Development of Highly Ductile (εf~49%), Biocompatible, and Eco-Friendly Mg-1Zn-1Ca Alloy and the Effect of Nano ZnO Reinforcement and Cryogenic Treatments

The development of eco-friendly magnesium (Mg)-based materials that possess acceptable mechanical properties, good biodegradability, and non-toxicity in biomedical applications has become more attractive in recent years, particularly for engineering and biomedical applications. This work investigates the effects of nano-ZnO (2 wt.%) reinforcement and cryogenic treatment (CT) on the microstructural, mechanical, thermal, and corrosion behavior of a non-toxic Mg-1Zn-1Ca alloy. Disintegrated melt deposition (DMD) was the synthesis starting point, while refrigeration at −20 °C (RF20) and liquid-nitrogen exposure at −196 °C (LN) were employed as the CT methods. CT significantly refined the grain size of the alloy and composite materials by more than 31.3%, down to 4.4–4.5 μm in diameter, leading to enhanced mechanical performance through grain boundary strengthening. RF20-treated Mg-1Zn-1Ca alloy exhibited the best damping properties (attenuation coefficient and damping capacity improved by 52.1% and 48.7%, respectively). Compressive response was also improved due to the combined effect of refined grains and reinforcement, with LN-treated Mg-1Zn-1Ca-2ZnO exhibiting the best combination of compression properties, i.e., YS—165 MPa, UCS—634 MPa, ε—43.6%, and Wf—175 MJ/m3. Ignition resistance was also improved with the addition of ZnO reinforcement (3.8% increase in ignition temperature). A significant reduction in corrosion rate was achieved with RF20 treatment, leading to corrosion rate reductions of 62% and 40% in PBS (simulated human body fluid) and salt solution, respectively, primarily due to equiaxed grains and stable microstructure. These results demonstrate the efficacy of ZnO reinforcement and CT conducted at different temperatures in selectively enhancing and tailoring the properties of eco-friendly, biocompatible Mg-alloys and composites for biomedical and strength-based applications.