Professional Documents
Culture Documents
Disclaimer
This report represents the findings of a mission
organised by Faraday Advance with the support of
DTI. Views expressed represent those of individual
members of the mission team and should not be
taken as representing the views of any other member
of the team, their employers, Faraday Advance or DTI.
Although every effort has been made to ensure the
accuracy and objective viewpoint of this report, and
information is provided in good faith, no liability can be
accepted for its accuracy or for any use to which it
might be put. Comments attributed to organisations
visited during this mission were those expressed by
personnel interviewed and should not be taken as
those of the organisation as a whole.
Whilst every effort has been made to ensure that the
information provided in this report is accurate and up
to date, DTI accepts no responsibility whatsoever in
relation to this information. DTI shall not be liable for
any loss of profits or contracts or any direct, indirect,
special or consequential loss or damages whether in
contract, tort or otherwise, arising out of or in
connection with your use of this information. This
disclaimer shall apply to the maximum extent
permissible by law.
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
CONTENTS
Acknowledgments
Foreword
Executive summary
1
1.1
Introduction
Background to mission
6
6
2
2.1
2.2
2.3
2.4
Objectives of mission
Specific objectives
Benefit to the UK
The mission
The mission team
8
8
8
8
9
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12
3.13
3.14
10
12
13
4.1
4.1.1
4.1.2
4.1.3
4.2
4.2.1
4.3
5
5.1
5.2
5.3
5.4
5.5
5.6
Developments in processing
25
and manufacture of components
from wrought magnesium
Extruded magnesium profiles
25
Take-Off (aerospace) project
27
VW 1-litre car
28
Formability
28
Sheet magnesium
28
Future development
31
requirements
Forged magnesium
32
Joining technologies and
integration
Laser welding
Friction stir welding (FSW)
Mechanical joining
Resistance spot welding (RSW)
Co-extrusion
Mechanical fasteners
33
35
36
36
37
37
38
14
14
14
16
16
16
17
18
20
6
6.1
6.2
6.2.1
6.2.2
6.2.3
6.2.4
6.3
6.3.1
6.3.2
6.3.3
6.3.4
21
6.4
21
23
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
ACKNOWLEDGMENTS
49
55
61
10
10.1
10.2
General conclusions
Research
Industry misconceptions
62
62
62
11
Key findings
63
12
Recommendations and
follow-up actions
64
7.1
7.2
7.2.1
7.2.2
7.2.3
7.3
7.4
7.4.1
7.4.2
7.4.3
7.4.4
7.4.5
7.5
8
8.1
8.2
8.3
A
B
C
D
Appendices
Host organisation profiles
Mission team details
List of exhibits
Glossary
49
49
49
50
51
51
51
51
52
52
52
52
54
55
58
59
65
69
75
77
3
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
FOREWORD
Chris Dagger
Divisional Managing
Director
Magnesium Elektron Ltd
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
EXECUTIVE SUMMARY
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
INTRODUCTION
Background to mission
1 Magnesium Automotive Potential, Australian Magnesium Corp Ltd Fact Sheet 11, December 2000, ABN 51 010 441 666:
www.austmg.com/documents/11_Auto%20Potentail.pdf
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
OBJECTIVES OF MISSION
Specific objectives
Benefit to the UK
The mission
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
Hydraulic press
Shot sleeve
Molten shot
Die cavity
Exhibit 3.1 HPDC cold-chamber process
10
Ram
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
11
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
Pouring of melt
Induction heating
Air cooling
Solidification nuclei
12
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
Pouring of melt
Protective cover gas
Ceramic container
Semi-solid slurry
TMELT ~ T LIQUIDUS
Solidification nuclei
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
200 m
Smelting
Cooling
Billet cutting
Billet reheating
Ram
15
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
3.6
Gravity casting
Sand casting
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
3.9
BCAST rheo-diecasting
(RDC) process
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
Twin-screw extruder
Inlet
High-speed
injection unit
Heated shot
sleeve
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
AZ
AM
AS
AE
Al, Zn
Al
Al, Si
rare earth
Advantages
Good strength
Improved ductility
Improved strength
Good high-temperature
at room
over AZ series
and creep
Disadvantages
temperature
Good castability
Mg2Si precipitates
Mg-RE precipitates
Limited castability
Limited castability
Low thermal
Limited room
strength
temperature
Low ductility
properties
Limited castability
Exhibit 3.11 ASTM magnesium die-casting alloy systems and relative performance
Alloy development
Creep resistance
(monolithic)
Specific strength
Light, high strength
Ductility
Mg-Sc-X-Y
(>300C)
Spray forming
TMT, MgLi
Mg-Y-RE- Zr
WE54 WE43
(200-300C)
Mg-Li-X
Mg-Si
Mg-Al-Ca(-RE)
Mg-Si
Mg-Al-Ca (-RE)
Mg-Li-X
Mg-Zn-Cu
Mg-Al-Ca-X
Mg-RE-Zn-Mn
(max 200C)
Mg-Al-Mn
Magnesium
GRAVITY
WROUGHT
Mg-Al-Si
AS 21
(max 150C)
Mg-Al-Zn
AM60 AZ91
(max 135C)
HPDC
Mg-Ag-RE-Zr
QE22 EQ21
(max 200-250C)
Mg-Al-RE
AE42
(max 175C)
Mg-Al-Zn
KEY
Creep resistance
Fibre and hybrid
reinforced Mg-alloys
(heterogeneous)
CTE
E-modulus
Creep
19
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
3.11
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
Gravity casting
alloy development
Other casting
technology research
21
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
Discharge direction
Solidified magnesium
Mould
Liquid magnesium
22
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
AZ31
AZ61
AZ80
AZ91
ZK60
WE43
Summary
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
24
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
Extrusion speed
Formability
limits
Formability
Limits
Hot
Hot
cracking
Cracking
Safe
Safe
processing
Processing
Billet Temperature
temperature
Billet
Hot cracking
25
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
Extrusion press
Billet
Die
Extruded profile
Ram
Seal
Hydrostatic medium
Seal
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
Original
AZ31-
AZ31
AZ31
AZ31
AW-6061
Substitution
Variant 1
Variant 2
hybrid
t (A1)
1.6 mm
1.6 mm
2.0 mm
1.8 mm
1.6 mm
t (A2)
1.6 mm
1.6 mm
2.0 mm
3.1 mm
1.6 mm
t (A2)
1.6 mm
1.6 mm
2.0 mm
1.6 mm
1.6 mm
E*1
100%
68%
82%
95%
>100%
-m
0%
35%
20%
15%
20%
Exhibit 4.3 LKR Take-Off project: magnesium PSU rail designs investigated
4.1.1
27
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
4.1.2
VW 1-litre car
Al-profile
Al-sheet
Mg-profile
Mg-sheet
Mg-casting + machined
MG-casting + part machined
CFK
Formability
4.2
Sheet magnesium
Stress (MPa)
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
AZ31-H24 RD
AZ31-H24 TD
AA6016-T4 RD
AA6016-T4 RD
Strain (%)
AEROSPACE
Cockpit carriers
Doors
Non-pressurised parts
Secondary structural parts
Seat components
Interior components
Covers, boxes and brackets
AUTOMOTIVE
Closures
Structural parts
Exterior panels
Crash relevant parts
CONSUMER GOODS
Leisure
Electrical equipment (laptop, mobile
phone and camera casings)
Structural parts
Exterior panels
Crash relevant parts
SZMT supplies sheet magnesium between
1-4 mm thick and heavy plate 20-100 mm
thick. The latter may be used for lightweight,
precision-machined products. SZMT
supplies AZ31 sheet magnesium in the
soft-annealed O condition, the typical
mechanical properties of which are
displayed in Exhibit 4.6.
Sheet quality
Soft-annealed O condition
130-160 MPa
Tensile strength, Rm
230-260 MPa
Uniform elongation, Ag
15-17%
17-22%
Thickness tolerance
0.07 mm
29
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
Hot bending
Hot stamping
Superplastic forming (SPF)
Warm hydroforming
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
without
lubrication
optimised
lubrication
Exhibit 4.8
Influence of lubrication on rolling
magnesium sheet
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
Forged magnesium
32
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
JOINING TECHNOLOGIES
AND INTEGRATION
Exhibit 5.1 HPDC cross-car beam displaying high levels of part and
function integration
33
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
Laser welding
Base metal
Fusion zone
Coarse grained
parent material
Fine grained
fusion zone
No grain coarsening
adjacent fusion zone
35
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
AZ31
AZ61
Al-Mg dissimilar FSW
AZ31
AC120
Mechanical joining
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
Exhibit 5.5
Cold riveting of AZ31
extrusions, and finite element
process simulation
5.4
Co-extrusion
37
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
5.6
Mechanical fasteners
Exhibit 5.8
New thread-forming
screw for fastening to
magnesium castings
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
Heat radiation
1
1 Aluminium foam
2 Thread bush
3 Foamable magnesium
39
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
MAGNESIUM SURFACE
TREATMENTS
1,100
Corrosion performance of
various magnesium and
aluminium alloys
1,000
40
Exhibit 6.1
900
800
700
ZE 41
600
QE 22
500
A Z91C
400
300
200
100
C 355
A 201
A 356
A 203
A 357
A 206
W E 43
W E 54
Elektron 21
A Z91E
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
6.1
NANOMAG
Exhibit 6.2
Closed-field
power supply
Sputter power
supply: bipolar
pulsed DC
V
V
Ar
Substrate bias:
bipolar pulsed DC
V
41
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
Exhibit 6.3
PECVD coating process
OCH 3
OCH 3 - Si OCH 3, O 2
QuickTime and a
decompressor
are needed to see this picture.
H2O, CO2 ,
CH 3OH
OCH 3
PUMP
13.5 MHz
Work piece
Exhibit 6.4
Sol-gel coating process
Solution
Hydrolysis
Substrate
Xerogel
Substrate
Dense
coating
Sol
Exhibit 6.5
Electrode 1
Electrode 2
Electrical pulses
Power supply
Plasma
discharge
Work
piece
Acousto
Electrolyte
hydrodynamic
generator
Electrolyte
Pump
Air
42
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
PAPVD
PECVD
Sol-gel
Keronite (PEO)
6.2.1
PAPVD
PECVD
6.2.3
Sol-gel
Keronite (PEO)
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
Highlights
6.3.1
Industrial perspective
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
GKSS
The GKSS magnesium research centre has
a dedicated corrosion department, headed
by Dr Wolfgang Dietzler. Its main
Exhibit 6.6
Electrochemical
pen used at GKSS
to determine
corrosion potential
Exhibit 6.7
Coating evaluation using
electrochemical, scanning pen
45
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
Yd
ire
cti
on
IFAM
X direction
AZ31
magnesium
AA5083
aluminium
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
Alkaline cleaning
Acid pickling
Cr6-free pretreatment
E-coat
Powder coat
Perceived technical/
economic barriers
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
6.4
Conclusions
48
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
7.1
Introduction
Total cost
Crash impact behaviour
Part integration
Stiffness
Surface finish
Durability
Supply chain maturity and stability
7.2.1
Magnesium supply
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
50,000
Exhibit 7.1
45,000
Western European
consumption of magnesium
for die-castings3
40,000
Tonnes
35,000
30,000
25,000
20,000
15,000
10,000
5,000
0
1993
1994
1995
1996
1997
1998
1999
2000
2001
2002
2003
2 Robert L Edgar, The Magnesium Industry Past, Present and Future, in: Proceedings of the 60th World Magnesium Conference, Stuttgart, May 2003, published
by International Magnesium Association (IMA)
3 Source data: International Magnesium Association (IMA)
50
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
Wrought alloys
Automotive applications
7.4.1 Powertrain
The powertrain is the part of the vehicle
with one of the largest potentials for weight
reduction, and is also one of the greatest for
potential volume magnesium applications.
In 2004 BMW launched a composite block
consisting of an inner casting made from
100,000
Exhibit 7.2
North and South American
consumption of magnesium
for die-castings3
Tonnes
80,000
60,000
40,000
20,000
0
1993
1994
1995
1996
1997
1998
1999
2000
2001
2002
2003
4 S Schumann & H Friedrich, The Route from the Potential of Magnesium to Increased Application in Cars, in: Proceedings of the 60th World Magnesium
Conference, Stuttgart, May 2003, published by IMA
51
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
Aerospace
Rail
Military
Information and communications
technologies
Power generation
Leisure
Medical
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
Exhibit 7.5
HPDC magnesium
seat frame
53
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
Conclusions
54
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
EU research projects
MG-CLUSTER
Coordinator: CRF (Italy)
This cluster has been organised to promote
a synergic effect from multiple results of the
different projects and to integrate the
necessary large quantity of activities in an
effective way, such that it will be possible to
embrace almost all kinds of application in
the field of the automotive industry.
MG-CHASSIS
Coordinator: IFAM (Germany)
The objective of the project is to develop a
manufacturing technology for the production
of lightweight magnesium chassis
components for high-toughness applications
(eg wheels, chassis), and to validate this for
two demonstrators. New magnesium alloys
with improved mechanical properties and
better corrosion resistance will be used, and
improved joining techniques. A fatigue-life
estimation method and quality-assurance
methods for highly loaded parts will
contribute to the design guidelines for
magnesium components.
55
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
Project title
Completion
date
EU funding
()
UK
FP4 projects
Design and processing of selectively reinforced Mg-based components
1998
1998
1999
1999
2000
2000
2000
2001
2001
2001
FP5 projects*
Development of novel materials in mechanical engineering
2002
22,006
2002
650,000
2003
1,578,739
2004
1,447,145
2004
975,800
2004
500,469
2004
2,306,033
2005
2,648,965
2005
3,386,475
2005
1,705,509
2005
117,600
2005
1,849,395
2005
1,275,351
FP6 projects
MAGFORGE
2007
* EU FP5: Total EU funding around 15.8 million, ie total project value around 31.6 million (~22.5 million);
UK involvement 3 from 13 projects
56
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
MG-ENGINE
Coordinator: Riso (Denmark)
The objective of the project is to develop
new magnesium alloys with improved hightemperature properties, to develop a
generic engine-block design, and to
manufacture engine-block prototypes. It will
take into consideration traditional casting
processes, but material will be improved by
modification of existing magnesium alloys
to increase the mechanical properties at
high temperature. Gluing and fastening
techniques for high temperature are
fundamental topics, which will be examined
in synergy with project MAGJOIN.
The total cost of the MG-ENGINE project is
4.1 million. The partners are: Volvo (Sweden),
Renault (France), Norsk Hydro (Norway),
Noranda (Canada), Honsel (Germany), CRF
(Italy), DaimlerChrysler (Germany), BMW
(Germany), Adam Opel (Germany).
NANOMAG
Coordinator: CRF (Italy)
The objective of the project is to develop
new corrosion and abrasion resistant
coatings for the protection of magnesium
parts, by using clean, environmentally
friendly and economic processes.
MAGJOIN
Coordinator: CRF (Italy)
This project was completed in 2003 at a
cost of 3 million, and established a stateof-the-art for processes and metallurgy for
mixed joints. A suitable configuration of
weldable joint by laser and arc processes
was described, and some specific joints
were selected for further experimentation.
Study and definition of metallurgical effect
on weldability of mixed joints was
completed, and a list of filler materials
possible for mixed joints was collected.
Filler materials of different chemical
57
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
MAGNEXTRUSCO
Coordinator: Audi AG (Germany)
The project aims to develop a new process
for the production of lightweight, costeffective and safe magnesium structures,
based on the hydrostatic extrusion principle.
One section of the MAGNEXTRUSCO
project focuses on the development of an
efficient process for magnesium extrusion,
including development of improved alloys
and billets as well as the study of processing
techniques. The expertise on joining of
magnesium structural parts will be obtained
from the recently started MAGJOIN project.
The exchange of know-how is secured,
58
Additional projects
LKR
MMC pistons (ALICE)
Co-extrusion of magnesium core with
aluminium outer layer (cooperation
with EADS)
Round-robin on recycling of magnesium
(Noranda Tech Centre, BMW, Magnola)
Major lightweighting project starting
in 2005
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
Meridian
MAGDOOR
New development with Norsk Hydro
engine oil-pan in anti-creep alloy
Crash research MEPROMA. Partners:
Renault, Volvo, Norsk, VW
GKSS
Many international project collaborations:
EU project MAGNEXTRUSCO:
2.5 million. Partners: Audi, IBF, TNO,
GKSS, Boliden, Rond, UUKV, IRF.
Hydrostatic extrusion
EU project MAGFORGE. Partners include
TNO, GKSS, IMA, TU Hamburg, Monash
University (Australia)
Joining: European Fitness for Service
Network (FITNET) (thematic network)
WEL-AIR EU project on laser beam
welding looking at T-joint skin-stringer
EU project Mag for Aero run by
Airbus Ottobrunn
Networks
Network industrial community for
promotion of light metal research (RWTH
involved)
FITNET EU Fitness for Service
thematic network (GKSS involved)
8.3
IFAM
MG-CHASSIS: 5.1 million. Partners:
IFAM, CRF, Speedline (withdrew), VW,
Opel, DaimlerChrysler, Chalmers
University, Dead Sea Magnesium, CBF
Darmstadt, Volvo. Ends January 2005
requesting extension
MG-ENGINE
MAGJOIN
MG-CLUSTER for above three projects
(Riso, IFAM, CRF)
CRF
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10
10.1
GENERAL CONCLUSIONS
Research
10.2
Industry misconceptions
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11
KEY FINDINGS
Casting technologies
Surface treatments
A series of new coatings for magnesium
is on the horizon, each with unique
properties. Considerable effort is still
required to improve scale-up of these
technologies, at which point the economics
of using these techniques will become
more desirable. Like joining technologies,
these may become fundamental enabling
technologies for magnesium and its future
growth and diversification.
63
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12
RECOMMENDATIONS AND
FOLLOW-UP ACTIONS
64
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Appendix A
HOST ORGANISATION PROFILES
ARC Leichtmetallkompetenzzentrum
Ranshofen GmbH (LKR)
www.lkr.at
Lamprechtshausenerstrae
Postfach 26
5282 Ranshofen
AUSTRIA
Dr-Ing H Kaufman
Director
T +43 7722 83333 7007
F +43 7722 83333 2
Dipl-Ing Rudolf Gradinger
Head of Lightweight Design
T +43 7722 83333 7007
F +43 7722 83333 2
rudolf.gradinger@arcs.ac.at
LKR Light Metal Competence Centre,
Ranshofen has 40 employees focused on
R&D in light metals, particularly Al and Mg.
LKR, a 100% subsidiary of the Austrian
Research Centres (ARC), provides contract
consultancy and R&D for industry, and has a
turnover of ~5 million. Its three key areas
of competence are materials, processing
technologies, and manufacturing. LKR
emerged from the former research
department of Austria Metall AG (AMAG),
the leading national aluminium-processing
company, and is therefore proficient in
working on light metals.
BMW Group
www.bmwgroup.com
FIZ Research & Innovation Centre
Munich
GERMANY
Dr-Ing A Istrate
Innovationsingenieur
T +49 89 382 39123
F +49 89 382 30417
adrian.istrate@bmw.de
Some 5,000 researchers, engineers and
technicians work at the FIZ, although BMW
Group employs over 105,000 people in
various countries globally.
BMW Group is the only global manufacturer
of automobiles and motorcycles that
concentrates entirely on premium standards
and outstanding quality for all its brands and
across all relevant segments. BMW
recognises the need for R&D, which is
demonstrated through its products. The
emphasis on R&D is also demonstrated by
this companys R&D spend, which has been
above 2 million for the last two consecutive
years, slightly above 10% of profit.
65
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Gieerei-Institut
Intzestrae 5
D-52072 Aachen
GERMANY
66
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Salzgitter AG
(Meeting at GKSS. Co-host with GKSS)
www.salzgitter-ag.de
www.szmt.de
Salzgitter Magnesium-Technologie GmbH
(SZMT)
Eisenhttenstrae 99
38239 Salzgitter
GERMANY
Dr Peter Juchmann
Managing Director
T +49 5341 21 39 57
F +49 160 47 12 490
juchmann.p@salzgitter-ag.de
As a young subsidiary of Salzgitter AG,
Salzgitter Magnesium-Technologie GmbH
(SZMT) is dealing with the development,
production, application and sales of
high-quality magnesium flat-rolled products.
The company offers an efficient technology
and material partnership for product
development and series applications.
IFAM
www.ifam.fhg.de
Fraunhofer-Institut fr Fertigungstechnik und
Angewandte Materialforschung
Wiener Strae 12
D-28359 Bremen
GERMANY
Mr Franz-Josef Woestmann
Head of Department Casting Technology
T +49 421 2246 225
F +49 421 2246 77 225
woe@ifam.fhg.de
Fraunhofer IFAM offers R&D services,
optimisation of casting processes,
and technology transfer in the following
areas of technology:
HPDC (hot and cold chamber)
Thixocasting
Squeeze casting
IFAM has recently installed new die-casting
equipment and is looking to engage in new
collaborative R&D programmes.
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Via Glair 41
11029 Verres
ITALY
Strada Torino 50
10043 Orbassano (TO)
ITALY
Marco Parma
Plant and Business Unit Manager
T +39 0125 922 301
F +39 0125 922 211
mparma@meridian-mag.com
Silvio Corrias
Head of Materials Engineering Department
Advanced Process Technologies
T +39 011 9083 354
F +39 011 9083 666
silvio.corrias@crf.it
1
1
4
7
x
x
x
x
420 ton
900 ton
1,500 ton
2,500 ton
68
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Appendix B
MISSION TEAM DETAILS
The mission team comprised nine delegates from the UK, listed in Exhibit B.1. Further details are given on
the following pages.
Name
Original
Organisation
AZ31Location
AZ31
AZ31
Representing
AZ31
Dr Tim Wilks
Magnesium Elektron
Manchester
Materials supplier
Mr Steve Brown
Meridian Technologies
Sutton-in-Ashfield
Dr Steve Hutchins
Keronite
Cambridge
Mr Rob Butler
Superform Aluminium
Worcester
Prof Z Fan
Uxbridge
Academia
Dr Geoff Scamans
Innoval Technology
Banbury
Technology consultancy
Dr Roger Darlington
Faraday Advance
Nuneaton/Oxford
Mission coordinator
Dr Martin Kemp
Melton Mowbray
Government agency
Mr Frank Rott
London
Government agency
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Dr Tim Wilks
Technical Manager (UK)
Magnesium Elektron Ltd (MEL)
Mr Steve Brown
Business Development Manager
Meridian Technologies Inc (UK)
PO Box 23
Swinton
Manchester
M27 8DD
UK
www.magnesium-elektron.com
Orchard Way
Calladine Business Park
Sutton-in-Ashfield
Nottinghamshire
NG17 1JU
UK
www.meridian-mag.com
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Dr Stephen Hutchins
Commercial Director
Keronite Ltd
Mr Rob Butler
Development Manager
Superform Aluminium
Granta Park
Great Abington
Cambridge
CB1 6GP
UK
www.keronite.com
Cosgrove Close
Blackpole
Worcester
WR3 8UA
UK
www.superform-aluminium.com
71
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72
Dr Geoff Scamans
Principal Scientist
Innoval Technology Ltd
Beaumont Close
Banbury
Oxfordshire
OX16 1TQ
UK
www.innovaltec.com
Innoval Technology Ltd is a materials
consultancy that specialises in light metal
production and utilisation in automotive,
architectural and packaging applications.
Formed in 2003, the company presently has
29 employees and an annual turnover of
2.7 million (2003).
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
Dr Roger Darlington
(Mission Coordinator)
Faraday Advance
Begbroke Business & Science Park
Sandy Lane
Yarnton
Oxford
OX5 1PF
UK
www.faraday-advance.net
Faraday Advance one of 24 Faraday
Partnerships is dedicated to improving the
competitiveness of UK industry through
more effective interactions between the
Science, Engineering and Technology (SET)
base in advanced materials and technologies
for the automotive and aerospace industries.
With six employees, it has an annual
turnover of 1.5 million.
Dr Martin Kemp
International Technology Promoter
Advanced Materials, Europe
DTI Global Watch Service
Pera Innovation Park
Melton Mowbray
Leicestershire
LE13 0PB
UK
www.globalwatchonline.com/itp
The International Technology Promoters (ITP)
network, funded through the DTI Global
Watch Service and managed by Pera
Innovation Ltd, is designed to facilitate
internationally based partnerships. The role
of the 18 ITPs is to provide direct assistance
to UK companies in order to raise
awareness of, and provide access to,
technology-based opportunities with the
worlds leading investors in R&D.
ITP support ranges from providing
straightforward information and referrals to
more in-depth assistance, perhaps involving
the setting up of licensing arrangements, or
guidance in the early stages of the transfer
of a product, technology, process or quality
improvement technique.
73
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Mr Frank Rott
Assistant Director, Head
DTI Global Watch Service
151 Buckingham Palace Road
London
SW1W 9SS
UK
www.dti.gov.uk
www.globalwatchonline.com
The DTIs Global Watch Service provides
support dedicated to helping UK
businesses improve their competitiveness
by identifying and accessing innovative
technologies and practices from overseas.
The Service comprises:
INFORMATION a unique website
delivering immediate and innovative
support to UK companies; plus a free
monthly magazine showcasing the latest
technologies and best practices from
around the world.
MISSIONS enabling small groups of
UK experts to visit leading overseas
technology organisations to learn vital
lessons about innovation and its
implementation to benefit entire
industries and individual organisations.
SECONDMENTS helping SMEs to send
employees abroad or receive key people
from overseas, secondments are an
effective way of acquiring knowledge,
skills, technologies and connections.
TECHNOLOGY PARTNERING free,
flexible and direct assistance delivered to
UK companies by a network of 18
International Technology Promoters (ITPs),
providing support ranging from information
and referrals to more in-depth assistance.
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Appendix C
LIST OF EXHIBITS
Exhibit
Page
Caption
2.1
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12
3.13
3.14
3.15
10
12
13
14
15
15
15
16
17
18
19
19
21
22
22
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
25
26
27
28
29
29
30
31
32
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
33
35
35
36
37
37
38
38
39
HPDC cross-car beam displaying high levels of part and function integration
InMaK: applied research into the manufacture of magnesium structures
Laser welding of magnesium sheet: AZ31 (2-mm thick), 7 m/min, 3.3 kW
Friction stir welded (FSW) Mg and Mg:Al sheets
Cold riveting of AZ31 extrusions, and finite element process simulation
LKR co-extrusion research
Conventional steel threaded insert used with magnesium HPDCs
New thread-forming screw for fastening to magnesium castings
New metal foam threaded-insert technology
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Exhibit
Page
Caption
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
40
41
42
42
42
45
45
46
7.1
7.2
7.3
7.4
7.5
7.6
50
51
52
53
53
53
8.1
56
B.1
B.2
69
69
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Appendix D
GLOSSARY
A
m
2D
3D
Al
AHC
AMC
Ar
ARC
ASTM
BCAST
BIW
BMBF
C
Ca
CFK
CH3OH
CO2
Cr
Cr6
CRF
CTE
CTI
Cu
CVD
DC
dm
DTI
EADS
EB
EC
ELV
EU
F
Fe
FEA
FP4
FP5
FP6
FSW
ft
H2
microamp
micrometre
two-dimensional
three-dimensional
aluminium
AHC-Oberflchentechnik GmbH (Germany)
Australian Magnesium Corp Ltd
argon
Austrian Research Centres
American Society for Testing and Materials (USA)
Brunel Centre for Advanced Solidification Technology (UK)
(automobile) body-in-white
Bundesministerium fr Bildung und Forschung (Germany)
degrees Celsius
calcium
carbon fibre composite
methanol
carbon dioxide
chromium
hexavalent chromium
Centro Ricerche Fiat (Italy)
coefficient of thermal expansion
Castings Technology International (UK)
copper
chemical vapour deposition
(1) direct-chill (casting); (2) direct current
decimetre
Department of Trade and Industry (UK)
European Aeronautic Defence and Space Company NV (Netherlands)
electron beam
European Commission
end-of-life vehicle
European Union
fluorine
iron
finite element analysis
Framework Programme 4 (EU)
Framework Programme 5 (EU)
Framework Programme 6 (EU)
friction stir welding
foot
hydrogen
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H2O
HAZ
HDO
HIP
HPDC
IFAM
IFUM
IMA
IP
IPR
ITP
IW
kg
km
kt
kW
LAFS
LCA
Li
LKR
LPDC
m
MEL
mg
Mg
Mg2Si
MHz
MIG
min
mm
MMC
MMW
Mn
MPa
mpg
MPI
mpy
MRI
mV
NaCl
Nd
NRC
NVEB
O2
OCH3
OEM
PAPVD
PECVD
78
water
heat-affected zone
HDO Druckgu- und Oberflchentechnik GmbH (Germany)
hot isostatic press
high-pressure die-casting
Institut fr Fertigungstechnik und Angewandte Materialforschung (Germany)
Institut fr Umformtechnik und Umformmaschinen (Germany)
International Magnesium Association (USA)
(1) instrument panel; (2) intellectual property
intellectual property rights
International Technology Promoter (DTI)
Institut fr Werkstoffkunde (Germany)
kilogram
kilometre
kilotonne
kilowatt
laser assisted friction stir (welding)
life-cycle assessment
lithium
Leichtmetallkompetenzzentrum Ranshofen GmbH (subsidiary of ARC)
low-pressure die-casting
metre
Magnesium Elektron Ltd (UK)
milligram
magnesium
magnesium silicide
megahertz
metal inert gas (welding)
minute
millimetre
metal-matrix composite
molten-metal-water
manganese
megapascal
miles per gallon
Meridian Magnesium Products of Italy srl
mils per year (mil = milli-inch = 0.001 inch)
Magnesium Research Institute (Israel)
millivolt
sodium chloride
neodymium
new rheocasting
non-vacuum electron beam (welding)
oxygen
methoxy group
original equipment manufacturer
plasma-assisted physical vapour deposition
plasma-enhanced chemical vapour deposition
MAG TECH 1: MAGNESIUM ALLOYS AND PROCESSING TECHNOLOGIES FOR LIGHTWEIGHT TRANSPORT APPLICATIONS A MISSION TO EUROPE
PEO
PMZ
PRC
PSU
PVD
R&D
RCP
RDC
RE
RSW
RTO
RWTH
Sc
SF6
Si
SiO2
SME
SO2
SPF
SPR
SSM
SZMT
t
Ti
TiH2
TIG
UK
ULM
US(A)
V
VDC
VICT
VW
y
YAG
Zn
Zr
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80
Printed in the UK on recycled paper with 75% de-inked post-consumer waste content
First published February 2005 by Pera Innovation Limited on behalf of the
Department of Trade and Industry
Crown copyright 2005
URN 05/538