BMBF-Project: „Mobil mit Magnesium – M³“
DFG-Project: in cooperation with the Max-Planck-Institut für Eisenforschung GmbH in Düsseldorf: “Fundamental investigation of the mechanism of deformation and recrystallisation of cold deformable Mg alloys micro-alloyed with rare earth elements and microstructure optimisation for the development of a new class of Mg alloys”
DFG-Project: “Developing new Mg alloys with optimised texture for enhanced formability" in cooperation with the NSF (National Science Foundation), USA, within the framework of the Materials World Network
AiF-Project: „Strukturbauteil aus geschmiedetem Magnesium”
AiF-Project with EUREKA-Status: „Development of high energy absorption wrought Mg alloys and manufacturingtechnologies for body protective safety equipment”
Twin Roll Caster
BMBF-Project: „Mobil mit Magnesium – M³“
Project partners:
Salzgitter Magnesium Technologie GmbH, Ludwigsfelde
Böllhoff Systemtechnik GmbH, Bielefeld
AHC Oberflächentechnik GmbH, Kerpen
GP Innovationsgesellschaft mbH, Lübbenau
Porsche Engineering Group GmbH, Weissach
Universität Hannover, Hannover
Technische Universität München, München
Universität Stuttgart, Stuttgart
Daimler AG, Stuttgart
Project aims:
As the lightest of all metallic materials, magnesium and its alloys offer tremendous potential for structural applications in the field of modern lightweight engineering. The project “Development of a Stable Process Chain for the Production of Ultra-light Components from Magnesium Sheet for Transport Engineering Applications” (ULM) resulted in the successful fabrication of formable magnesium sheets that fulfilled specified industrial requirements. It is therefore now possible to manufacture high quality magnesium sheets on the basis of a variety of alloys.
At present, however, the limited range of properties of the various types of magnesium sheet available hinders widespread industrial use of these materials. This is largely a consequence of the hexagonal crystal structure of magnesium, which effectively precludes good formability at room temperature, with the result that further research and development is required in order to enhance the forming properties of magnesium alloys.
At the same time, economic production concepts are needed in order to alleviate the massive cost pressures faced by producers in this sector. This can be achieved by extending the range of properties of magnesium alloys on the one hand, and, on the other, by placing a strong emphasis on economic efficiency in the manufacture of the sheet itself. In response to these challenges, the aim of the current project is to exploit and apply know-how already acquired in the development of new magnesium alloys. In this context, application of twin-roll casting to produce strips that can then be warm rolled in subsequent stages to manufacture optimised sheet metal is set to play a significant role. This is in addition to traditional rolling methods, which are used exclusively to process starting materials that have already been enhanced in quality.
Here the emphasis is placed on the selection, characterisation, enhanced processing and evaluation of new magnesium alloys that meet the requirements of advanced production strategies. In particular, this includes extending the formability limits of magnesium sheet at lower processing temperatures.
Salzgitter Magnesium Technologie GmbH, Ludwigsfelde
Böllhoff Systemtechnik GmbH, Bielefeld
AHC Oberflächentechnik GmbH, Kerpen
GP Innovationsgesellschaft mbH, Lübbenau
Porsche Engineering Group GmbH, Weissach
Universität Hannover, Hannover
Technische Universität München, München
Universität Stuttgart, Stuttgart
Daimler AG, Stuttgart
Project aims:
As the lightest of all metallic materials, magnesium and its alloys offer tremendous potential for structural applications in the field of modern lightweight engineering. The project “Development of a Stable Process Chain for the Production of Ultra-light Components from Magnesium Sheet for Transport Engineering Applications” (ULM) resulted in the successful fabrication of formable magnesium sheets that fulfilled specified industrial requirements. It is therefore now possible to manufacture high quality magnesium sheets on the basis of a variety of alloys.
At present, however, the limited range of properties of the various types of magnesium sheet available hinders widespread industrial use of these materials. This is largely a consequence of the hexagonal crystal structure of magnesium, which effectively precludes good formability at room temperature, with the result that further research and development is required in order to enhance the forming properties of magnesium alloys.
At the same time, economic production concepts are needed in order to alleviate the massive cost pressures faced by producers in this sector. This can be achieved by extending the range of properties of magnesium alloys on the one hand, and, on the other, by placing a strong emphasis on economic efficiency in the manufacture of the sheet itself. In response to these challenges, the aim of the current project is to exploit and apply know-how already acquired in the development of new magnesium alloys. In this context, application of twin-roll casting to produce strips that can then be warm rolled in subsequent stages to manufacture optimised sheet metal is set to play a significant role. This is in addition to traditional rolling methods, which are used exclusively to process starting materials that have already been enhanced in quality.
Here the emphasis is placed on the selection, characterisation, enhanced processing and evaluation of new magnesium alloys that meet the requirements of advanced production strategies. In particular, this includes extending the formability limits of magnesium sheet at lower processing temperatures.
DFG-Project: in cooperation with the Max-Planck-Institut für Eisenforschung GmbH in Düsseldorf: “Fundamental investigation of the mechanism of deformation and recrystallisation of cold deformable Mg alloys micro-alloyed with rare earth elements and microstructure optimisation for the development of a new class of Mg alloys”
Project partner:
Max-Planck-Institut für Eisenforschung, Düsseldorf, Dr.-Ing. Stefan Zaefferer
Project aims:
The main goals of the project are to clarify the room temperature deformation mechanisms in RE-containing Mg alloys and to investigate the recrystallisation behaviour after cold deformation. The main focus of the investigations will be to gain a fundamental understanding of the basic mechanisms which lead to the significant changes in deformation behaviour and recrystallisation kinetics documented in a previous project. To this end, transmission electron microscopy (TEM) studies supported by ab initio calculations will be used to investigate the relationships between stacking fault energy (SFE) and different slip systems in selected RE-containing alloys.
A further aim of the project is to understand the basic mechanism of texture weakening during static recrystallisation of Mg-RE alloys. Experimental investigations using TEM and high resolution EBSD will be conducted, paying particular attention to the crystallographic orientations of nuclei during the initial stages of recrystallisation. The retarding influence of RE elements on the recrystallisation kinetics will be investigated by analysing the orientation relationships between the deformed matrix and the (growing) nuclei as well as the concentrations of RE elements and precipitates at grain boundaries during the early and intermediate stages of recrystallisation.
The ultimate goal of the project is to establish guidelines for the amount and type of RE elements leading to optimum mechanical properties. In this way we expect a more physics-based optimisation of new alloys for structural applications with enhanced room temperature deformability.
Max-Planck-Institut für Eisenforschung, Düsseldorf, Dr.-Ing. Stefan Zaefferer
Project aims:
The main goals of the project are to clarify the room temperature deformation mechanisms in RE-containing Mg alloys and to investigate the recrystallisation behaviour after cold deformation. The main focus of the investigations will be to gain a fundamental understanding of the basic mechanisms which lead to the significant changes in deformation behaviour and recrystallisation kinetics documented in a previous project. To this end, transmission electron microscopy (TEM) studies supported by ab initio calculations will be used to investigate the relationships between stacking fault energy (SFE) and different slip systems in selected RE-containing alloys.
A further aim of the project is to understand the basic mechanism of texture weakening during static recrystallisation of Mg-RE alloys. Experimental investigations using TEM and high resolution EBSD will be conducted, paying particular attention to the crystallographic orientations of nuclei during the initial stages of recrystallisation. The retarding influence of RE elements on the recrystallisation kinetics will be investigated by analysing the orientation relationships between the deformed matrix and the (growing) nuclei as well as the concentrations of RE elements and precipitates at grain boundaries during the early and intermediate stages of recrystallisation.
The ultimate goal of the project is to establish guidelines for the amount and type of RE elements leading to optimum mechanical properties. In this way we expect a more physics-based optimisation of new alloys for structural applications with enhanced room temperature deformability.
DFG-Project: “Developing new Mg alloys with optimised texture for enhanced formability" in cooperation with the NSF (National Science Foundation), USA, within the framework of the Materials World Network
Project partners:
Technische Universität Hamburg-Harburg, Hamburg
Prof. Dr.-Ing. Karl-Ulrich Kainer
University of Virginia, Charlottesville, USA
Assistant Professor Dr. Sean R. Agnew
Project aims:
Magnesium sheet alloys are in the spotlight of industrial interest worldwide with a view towards enhanced lightweight applications. However, there is a need for alloys with improved rollability and sheet formability. The objective of this project is to develop new magnesium alloys based on a better understanding of the influence of crystallographic texture and alloying elements on formability. While typical magnesium wrought alloys exhibit strong basal textures with only slight variations between them, it has recently been reported that alloys containing rare earth elements and/or yttrium can develop a more random type texture. Such a texture could improve formability as well as reduce the anisotropy of mechanical properties. Texture modification has been associated with changes in the recrystallisation mechanisms, but a more specific connection between alloying additions and mechanistic changes is required to develop an effective alloy design strategy. There will be a strong experimental focus in this project accompanied by crystal plasticity modelling of the influence of texture on the formability and thermodynamic modelling of phase stability in the partner project. This integrated experimental/modelling approach to alloy development will yield magnesium sheet alloys with tailored properties.
Technische Universität Hamburg-Harburg, Hamburg
Prof. Dr.-Ing. Karl-Ulrich Kainer
University of Virginia, Charlottesville, USA
Assistant Professor Dr. Sean R. Agnew
Project aims:
Magnesium sheet alloys are in the spotlight of industrial interest worldwide with a view towards enhanced lightweight applications. However, there is a need for alloys with improved rollability and sheet formability. The objective of this project is to develop new magnesium alloys based on a better understanding of the influence of crystallographic texture and alloying elements on formability. While typical magnesium wrought alloys exhibit strong basal textures with only slight variations between them, it has recently been reported that alloys containing rare earth elements and/or yttrium can develop a more random type texture. Such a texture could improve formability as well as reduce the anisotropy of mechanical properties. Texture modification has been associated with changes in the recrystallisation mechanisms, but a more specific connection between alloying additions and mechanistic changes is required to develop an effective alloy design strategy. There will be a strong experimental focus in this project accompanied by crystal plasticity modelling of the influence of texture on the formability and thermodynamic modelling of phase stability in the partner project. This integrated experimental/modelling approach to alloy development will yield magnesium sheet alloys with tailored properties.
AiF-Project: „Strukturbauteil aus geschmiedetem Magnesium”
Project partners:
Modell- und Formenbau GmbH Sachsen-Anhalt, Magdeburg
Weisensee Warmpressteile GmbH, Eichenzell
B&W Fahrzeugentwicklung GmbH, Oebisfelde
Forging of magnesium alloys is still a process only used for niche products. In spite of the need for light weight mass products, e.g., in automotive industry, and in spite of available technologies there is still no mass production of forged magnesium parts. Apart from the limited mechanical properties of the products also the cost intensive production chain prevents the establishment of magnesium forging as an accepted technology for production of serial parts.
The overall goal of this R&D project is to develop a processing chain from casting of the feedstock through the forging process to the final component. Of central importance is the availability of feedstock material at reasonable cost. At present, extruded billets are commonly used as feedstock since they exhibit a fine-grained, homogeneous microstructure, which is desirable for good forgeability. The extrusion process, however, is costly and consumes a considerable amount of energy. In this project the feasibility of using alternative feedstock material such as strip cast and subsequently rolled sheets with a fine recrystallised microstructure will be investigated. A major part of the research is dedicated to the development and optimisation of appropriate forging alloys.
Modell- und Formenbau GmbH Sachsen-Anhalt, Magdeburg
Weisensee Warmpressteile GmbH, Eichenzell
B&W Fahrzeugentwicklung GmbH, Oebisfelde
Forging of magnesium alloys is still a process only used for niche products. In spite of the need for light weight mass products, e.g., in automotive industry, and in spite of available technologies there is still no mass production of forged magnesium parts. Apart from the limited mechanical properties of the products also the cost intensive production chain prevents the establishment of magnesium forging as an accepted technology for production of serial parts.
The overall goal of this R&D project is to develop a processing chain from casting of the feedstock through the forging process to the final component. Of central importance is the availability of feedstock material at reasonable cost. At present, extruded billets are commonly used as feedstock since they exhibit a fine-grained, homogeneous microstructure, which is desirable for good forgeability. The extrusion process, however, is costly and consumes a considerable amount of energy. In this project the feasibility of using alternative feedstock material such as strip cast and subsequently rolled sheets with a fine recrystallised microstructure will be investigated. A major part of the research is dedicated to the development and optimisation of appropriate forging alloys.
AiF-Project with EUREKA-Status: „Development of high energy absorption wrought Mg alloys and manufacturingtechnologies for body protective safety equipment”
Project partners:
MK Technology GmbH, Lüdenscheid, Deutschland
Aero-Magnesium DE UG, Frankfurt/M., Deutschland
Dead Sea Magnesium Ltd, Beer Sheva, Israel
Project aims:
Aim of this R&D-project is the development of novel body protector systems for police forces consisting of magnesium sheets in order to significantly reduce the weight. New wrought Mg alloys with enhanced energy absorption will be developed to meet the strong requirements to the protector systems. The properties of Mg sheet-metals for body protection against hit, stab and ballistic threads will be guaranteed by thermodynamic-based alloy design and novel processing techniques like twin-roll casting and subsequent hot rolling. Special protective coating will be developed on base of composite coatings technology – newest thick and hard, but flexible chemical coatings for magnesium. The coating will improve both corrosion and wear resistance.
MK Technology GmbH, Lüdenscheid, Deutschland
Aero-Magnesium DE UG, Frankfurt/M., Deutschland
Dead Sea Magnesium Ltd, Beer Sheva, Israel
Project aims:
Aim of this R&D-project is the development of novel body protector systems for police forces consisting of magnesium sheets in order to significantly reduce the weight. New wrought Mg alloys with enhanced energy absorption will be developed to meet the strong requirements to the protector systems. The properties of Mg sheet-metals for body protection against hit, stab and ballistic threads will be guaranteed by thermodynamic-based alloy design and novel processing techniques like twin-roll casting and subsequent hot rolling. Special protective coating will be developed on base of composite coatings technology – newest thick and hard, but flexible chemical coatings for magnesium. The coating will improve both corrosion and wear resistance.
Twin Roll Caster
The development of new wrought magnesium alloys, in particular sheet materials, and their utilisation in industrial applications are major goals of the research topic “Lightweight Materials” in the HGF Programme “Advanced Engineering Materials” within the research area “Key Technologies”. A major obstacle in this context is the provision of suitable feedstock materials.
Twin roller casting is an excellent method for the generation of fine grained feedstock materials that can subsequently be warm-rolled to thin sheets. The R&D work concentrates on the optimisation of the processing parameters throughout the entire processing chain and the evaluation of the resulting sheet materials. Optimisation criteria also include those connected with subsequent processing steps such as deep drawing and coatings for corrosion protection. This work is supported by materials modelling activities which allow the simulation of thermomechanical processes and the mechanical behaviour of components. Optimised alloys produced on a near industrial scale can then be made available to interested industrial partners in order to demonstrate the potential of magnesium alloy sheet material in lightweight structural applications.
Twin roller casting is an excellent method for the generation of fine grained feedstock materials that can subsequently be warm-rolled to thin sheets. The R&D work concentrates on the optimisation of the processing parameters throughout the entire processing chain and the evaluation of the resulting sheet materials. Optimisation criteria also include those connected with subsequent processing steps such as deep drawing and coatings for corrosion protection. This work is supported by materials modelling activities which allow the simulation of thermomechanical processes and the mechanical behaviour of components. Optimised alloys produced on a near industrial scale can then be made available to interested industrial partners in order to demonstrate the potential of magnesium alloy sheet material in lightweight structural applications.
Giesswalzanlage