A high-strength and high-elongation soluble Mg-Gd-Y-Zn-Zr-Cu alloy for fracturing tool fabrication

• Developed advanced soluble Mg7.3Gd3.0Y1.0Zn0.2ZrxCu alloys for fracturing tools. • TYS > 325 MPa, EL > 13.8 %, corrosion rate: 49 to 1367 mm/y in 3 wt% KCl at 93 °C. • Low RE content → low deformation resistance → low extrusion temp → fine grain size. • The 1.2 wt%Cu alloy has 349.6 MPa TYS, 14.3 % EI, 783.7 mm/y corrosion rate. Developing soluble magnesium alloys with excellent comprehensive mechanical properties is key for shale oil/gas fracturing tools. In this study, Mg-7.3Gd-3.0Y-1.0Zn-0.2Zr-xCu (x = 0.2–1.8 wt%) alloys were prepared via direct cooling casting and extrusion. They exhibited a tensile yield strength (TYS) of over 325 MPa and an elongation (EL) of over 13.8 %, mainly due to their fine grain size (≈50 µm) from dynamic recrystallization at the relatively low extrusion temperature (400 °C). As Cu content rose, corrosion rate increased, yet mechanical properties stayed stable. The Mg-7.3Gd-3.0Y-1.0Zn-0.2Zr-1.2Cu alloy showed the best properties: a TYS of 349.6 MPa, an EL of 14.3 %, and a corrosion rate of 783.7 mm/year in 3 wt% KCl at 93 °C.