Browse Topic: Magnesium

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Unlocking Simulation Study of Convection Heat Transfer Magnesium Strip Solid Spring Mechanism2026-99-10098/7/2026
This study investigates the convective heat transfer mechanism in the unlocking process of magnesium strip-based solid propellant mechanisms, supported by numerical simulations. Through developing a multiphysics coupled model for the unlocking mechanism, we analyze magnesium strip fracture and unlocking processes, revealing how convective heat transfer affects unlocking duration. The simulation results demonstrate excellent agreement with experimental data, providing theoretical guidance for engineering design of magnesium strip-based solid propellant systems.
Wang, Haoxu, Zhong, Jianlin
Lightweight Magnesium Nanocomposites with Enhanced Wear Resistance for Landing Gear Application2026-26-07516/1/2026
This study systematically evaluated the wear resilient performance of AZ61 magnesium alloy reinforced with 15 wt.% SiC and diverse amounts of multi-walled carbon nanotubes (MWCNTs) under dry sliding circumstances adopting pin-on-disc apparatus (ASTM G99). To identify the influence of factors like sliding speed (SS) (1-3 m/s), axial load (AL) (10-30 N), and MWCNT concentration (0-3 wt.%) that affect tribological performance, experiments were developed using a Central Composite Design (CCD) under Response Surface Methodology (RSM). SEM micrographs revealed a dispersion optimum near 2 wt.% MWCNT, where CNTs anchor to SiC and bridge the α-Mg matrix, while 3 wt.% shows agglomerates and micro-voids. Findings showed that wear loss (WL) and friction coefficient (CoF) was greatly amplified by increasing AL owing to localized heating and contact stresses. A compacted tribolayer was formed by increasing SS, which decreased WL but marginally raised the CoF. At low AL (10 N), SS (2.09 m/s), and 2.12 wt.% MWCNT, the wear resistance was significantly improved by improving load transfer and creating a lubricating carbon-rich coating, resulting in a decreased WL of 0.006 g. The CoF persisted within the range of 0.19 to 0.28. Agglomeration of MWCNTs caused increased WL and CoF when the MWCNT content is increased above 2 wt.%. Worn-surface microscopy at the optimum showed fine wear tracks and a continuous carbon/oxide glaze, evidencing a lubricious CNT-rich third-body film, whereas high AL/low MWCNT produced deep grooves and delamination.
Senthilkumar, N.
Predictive Model and Analysis of the Resultant Force in the Dry Machining of Mg-4Zn/Si 3 N 4 Nanocomposites2026-26-07626/1/2026
The development of lightweight materials for use in aerospace and automotive applications is extremely significant. Magnesium (Mg)-based alloys and composites are good candidate materials from the perspective of low density, good specific strength, and abundance. The Mg-4Zn alloy is one such alloy, which is a lightweight, biocompatible, and eco-friendly Mg-based alloy. In spite of these advantages, there is a strong need and scope to improve its wear resistance and mechanical properties. Mg-4Zn nanocomposites with Si3N4 reinforcements (a biocompatible bioceramic) are hypothesized to possess superior properties. Microstructural analysis of the vacuum stir-cast nanocomposites confirms grain refinement and a consequent increase in microhardness with an increase in Si3N4 reinforcement wt.%. The addition of Si3N4 reinforcement to improve the properties of the Mg-4Zn alloy could introduce challenges in machining. To make products from the nanocomposites, machining them with minimal subsurface defects with minimal energy consumption under sustainable conditions is necessary. The resultant machining force (Fr) is a good indicator of subsurface quality and energy consumption in machining. To investigate the effect of reinforcement wt.% and machining parameters on the resultant machining force, dry turning experiments on the vacuum stir-cast Mg-4Zn/Si3N4 nanocomposites were carried out based on the response surface methodology-based Box-Behnken design. It is observed that the regression model for Fr is influenced by the reinforcement wt.%, cutting speed, feed rate, and depth of cut and also their squares and their mutual interactions. Increase in microhardness, variation in porosity, thermal softening, and strain hardening contribute to the variation in Fr. Minimal Fr and hence better subsurface quality and lower energy consumption are obtained at mid values of Si3N4 reinforcement wt.% and cutting speed and low values of feed rate and depth of cut. The developed model is an excellent fit, with R2 and adjusted R2 values of 0.9907 and 0.9799, respectively.
N, Anand, Shaju, Tony M, G, Nagamalleswara Rao, D, Bijulal, K, Jayaprakash Reddy, K, Vijayan, Chaman, Joji J
Wear Resilience Characteristics of Silicon Nitride Strengthened AZ31 Magnesium Composite2026-26-07406/1/2026
To develop magnesium matrix composites, ceramic silicon nitride (Si3N4) particles are added to the magnesium (AZ31) matrix at 2 wt.%. The composite is produced via disintegrated melt deposition vacuum-stir-casting procedure. Microstructural studies reveal the presence of Si3N4 particles and their uniform spreading. An L9 orthogonal array, planned using Taguchi’s experimental design, is selected for three wear parameters; axial load (AL), rotational speed (RS), and time duration (TD) with trials as per the G99 standard in the pin-on-disc apparatus to assess the wear resilient of the composite. Experimental results show an increase in axial stress, and wear loss (WL) increases dramatically. Because the area of contact shrinks as RS increases, WL diminishes dramatically. When the AL is low, the friction coefficient (CoF) increases, and when the AL is large, CoF drops. When the RS is increased, CoF decreases. To optimize multiple responses effectively, the TOPSIS (Technique for Order Preference by Similarity to Ideal Solution) approach was adopted. According to the analysis, the ideal combination turned out to be a 10 N A, an RS of 275 rpm, and a TD of 1000 seconds. ANOVA results show that AL (56.99%) and RS (27.2%) contribute more, with a regression coefficient of 92.99%. Abrasive and adhesive wear mechanisms are observed from the worn-out surface micrographs.
Senthilkumar, N., Dhinakar Raj, C K
Recent Advances in Multivalent-Ion Batteries for Next-Generation Energy Storage14-15-02-00104/24/2026
As global demand for sustainable energy solutions increases, there is a push to develop alternatives to lithium-ion batteries, which face limitations in cost, resource availability, and safety. In particular, multivalent-ion batteries based on magnesium, calcium, zinc, and aluminum have emerged as promising candidates due to their ability to transfer multiple electrons per ion, offering higher volumetric energy density and greater material abundance. This review examines recent advances in electrode and electrolyte development for these systems, highlighting cathode innovations such as cobalt sulfides for magnesium, NASICON-type and redox-coupled materials for calcium, molybdenum trioxide frameworks for zinc, and organic and composite electrodes for aluminum. Electrolyte research has produced improved ionic transport and stability through solvation tuning, hybrid and polymer systems, and deep eutectic solvents. Interfacial engineering is identified as a key enabler for enhancing reversibility, dendrite suppression, and long-term cycling stability. A comparative analysis of the different chemistries found that zinc-ion systems are closest to commercial deployment, aluminum-ion batteries are advancing for grid and flexible devices, and magnesium and calcium-ion batteries hold long-term potential for high-energy applications. The study concludes with future research directions emphasizing solvation control, sustainable materials, and intelligent diagnostics to achieve scalable multivalent battery technologies.
Mittal, Vikram, Shah, Rajesh, Li, Ivy
Multi-Material Topology Optimization Using Difference-Based Equivalent Static Load Method2026-01-01734/7/2026
Topology optimization (TO) has become a powerful tool for generating lightweight structural designs. TO has been widely applied to linear static problems, where analytical sensitivities are easy to obtain. However, crashworthiness design requires nonlinear dynamic analysis, for which analytical sensitivities are generally not available. To extend TO into crash problems, approximation methods such as the Equivalent Static Load (ESL) method have been developed. ESL replaces the nonlinear problem with a series of linear static subproblems, ensuring that the displacement fields match at certain time steps. These subproblems can then be efficiently solved using standard TO techniques. A key limitation of ESL is that it relies on the initial mesh for all subproblems, which reduces accuracy for highly nonlinear crash responses. To address this, Triller proposed the difference-based ESL (DiESL) method, which updates the mesh in each subproblem to the deformed configuration, therefore improving approximation accuracy. However, existing DiESL implementations are restricted to single-material topology optimization (SMTO), where elements can be either solid or void. In contrast, multi-material topology optimization (MMTO) allows multiple material candidates per element, offering greater design freedom and the potential for better solutions. For crashworthiness applications, MMTO can leverage low-density materials (e.g., aluminum or magnesium) to form thick members that resist buckling, while using high-strength, high-density materials (e.g., steel) in critical stress regions to prevent yielding. By combining MMTO with DiESL, nonlinear crash performance can be further improved, offering a promising framework for lightweight and crashworthy structural design.
Huang, Yuhao, Kim, Il Yong
AI Breakthrough Unlocks ‘New’ Materials to Replace Lithium-Ion BatteriesTBMG-5388210/1/2025
In research published in Cell Reports Physical Science, the NJIT team led by Professor Dibakar Datta successfully applied generative AI techniques to rapidly discover new porous materials capable of revolutionizing multivalent-ion batteries. These batteries, using abundant elements like magnesium, calcium, aluminum, and zinc, offer a promising, cost-effective alternative to lithium-ion batteries, which face global supply challenges and sustainability issues.
Self-Piercing Riveting (SPR) of Magnesium High Pressure Die Casting and Dissimilar Materials2025-01-82314/1/2025
Solid state joining processes are attractive for magnesium alloys as they can offer robust joints without the porosity issue typically associated with welding of magnesium and dissimilar materials. Among these techniques, Self-Piercing Riveting (SPR) is a clean, fast and cost-effective method widely employed in automotive industry for aluminum alloys. While SPR has been proven effective for joining aluminum and steel, it has yet to be successfully adapted for magnesium alloy castings. The primary challenge in developing magnesium SPR technology is the cracking of the magnesium button, which occurs due to magnesium's low formability at room temperature. Researchers and engineers approached this issue with several techniques, such as pre-heating, applying rotation to rivets, using a sacrificial layer and padded SPR. However, all these methods involve the employment of new equipment or introduction of extra processing steps. The aim of this work is to develop a SPR technique which adapts current SPR machines with minimal changes to existing processes to create crack-free joint between magnesium and dissimilar materials. In the current study, feasibility of joining coupons of typical structural materials including high strength steel, aluminum alloys and composite to magnesium high pressure die casting (HPDC) was investigated. It was demonstrated that a joint is achieved which is crack-free both internally and externally. Also, the lap shear strength of the joints was investigated. Given its flexibility in material selection and compatibility with existing SPR process lines, this method holds significant potential to facilitate more applications on materials with limited ductility.
Tabatabaei, Yousef, Wang, Gerry, Weiler, Jonathan
Microstructure, Tensile and Fracture Behaviors of Squeeze Cast Wrought Mg Alloy AZ802025-01-82304/1/2025
Wrought magnesium alloy AZ80 with a thick section of 20 mm was prepared by squeeze casting (SC) and permanent steel mold casting (PSMC). The porosity measurements of the SC and PSMC showed that the SC AZ80 had a porosity of 0.52%, which was the 77% lower than that (2.21%) of the PSMC counterpart. The microstructure analyses and phase identification indicated that the cast AZ80 alloy consisted of a primary α-Mg phase, eutectic Mg-Al-Zn phases and Al-Mn intermetallic. The fine primary α-Mg dendrites and a high amount of the intermetallic phase were present in the SC AZ80 alloy. The yield strength (YS), ultimate yield strength (UTS), elongation (ef), elastic modulus (E) and strain hardening rate of the cast AZ80 specimens were evaluated by tensile testing. The measured engineering stress versus strain curves showed that the SC AZ80 alloy exhibited 84.68 MPa in YS, 168.23 MPa in UTS, 5.07% in ef, and 25.1GPa in modulus while the YS, UTS and ef of the PSMC specimen were only 71.61 MPa, 109.04 MPa, 1.85% and 21.9GPa. The calculated resilience and tensile toughness indicated that the SC AZ80 was more capable of resisting energy loads in elastic deformation and had an ability to absorb energy during plastic deformation than that of the PSMC AZ80. Also, the analyses of the true stress versus strain curves revealed that, upon the onset of plastic deformation, the strain-hardening rate of the SC AZ80 sample was 10,341 MPa, which was 9% higher than that (9,489 MPa) of the PSMC AZ80 specimen. The obtained mechanical properties showcased the fit of the casting process to wrought magnesium AZ80 alloy, which was squeeze casting. The low porosity level, fine dendritic structure and a high content of intermetallic phase should be somewhat responsible for high mechanical properties of the SC AZ80 alloy.
Ying, Peilin, Hu, Henry, Hu, Anita, Shen, Wutian
Aluminum Foil for Sandwich ConstructionAMSA81596A (Current)3/27/2025
This specification covers the requirements of uncoated aluminum alloy foil for core materials required for structural sandwich construction.
AMS D Nonferrous Alloys Committee
Viscosity and Thermal Conductivity Characterization of Magnesium Oxide Nanofluids for Improved Automobile Thermal Management2024-01-52541/28/2025
Magnesium oxide (MgO) nanofluids are of great interest for enhancing the performance in thermal management especially in automotive applications, where efforts have been made to reduce parasitic losses from traditional cooling systems. These findings highlight the effects of Water–ethylene glycol and MgO nanofluids on viscosity and thermal conductivity in specific filling a gap in research that allows to clarify how these states behave at different temperature (T) and concentration (C) conditions. Test results demonstrate that the thermal conductivity of MgO nanofluids improved adequately /while its corresponding change in viscosity remained under control, affirming a significant improvement for energy savings by means heat transfer enhancement using new generation coolants based on this nano-additive. The results also provide useful information for design and development of automotive cooling systems, including real numbers on performance improvements that lead to more efficient and reliable thermal management designs.
Jeyanthi, P.
Characterization of Graphene and Titanium Carbide Reinforced Magnesium Alloy Composite for Transmission Housings in Automobile2024-01-523112/10/2024
This study presents the mechanical characterization studies on 3 wt.% graphene (Gr) filled magnesium matrix composite reinforced with different weight fractions (4, 8, 12, 16, and 20 wt.%) of titanium carbide (TiC) particles. The matrix is AZ91 alloy, and the nano magnesium composite (NMC) is fabricated via a squeeze casting approach. The lightweight NMC is a potential solution for the automobile industry, as it reduces greenhouse gas emissions and contributes to environmental sustainability. Gr is added to enhance the composite's thermal endurance and mechanical strength. Mechanical and corrosion studies are performed as per the ASTM standards. The inclusion of Gr and 16 wt.% TiC tends to enhance the mechanical durability and corrosion resilience of the NMC when compared with other fabricated composites and cast alloys. The uniform dispersal of NC and TiC and better mould properties lead to better strength. Higher inclusion of TiC (20 wt.%) leads to brittleness, thereby decreasing the overall wear loss by resisting abrasive, which lowers the composite's flexibility and strength. The potential mechanism of adhesive wear is shown by the fact that TiC and Gr decrease the intimate contact region between the composite and the EN31 counter-disc. Compared with as-cast alloy, AZ91+3%Gr+16%TiC produced 64.31% higher porosity, 19.50%, 26.69%, 59.45%, and 19.66% higher UTS, micro-hardness, impact, and flexural strength.
Senthilkumar, N.
Characteristics of Magnesium Composite Reinforced with Silicon Carbide and Boron Nitride via Liquid Stir Processing2024-01-523712/10/2024
The present aim of the investigation is to prepare and evaluate the excellence of boron nitride (BN) and silicon carbide nanoparticles on characteristics of magnesium alloy (AZ91D) hybrid nanocomposite. This constitution of AZ91D alloy hybrid nanocomposite is made through the liquid state processing route, which helps to improve the spread of particles in the AZ91D matrix. The impact of BN and SiC on microstructural and mechanical properties like tensile strength, hardness, and impact strength of AZ91D alloy composites are studied, and its investigational results are compared. Besides, microstructural studies have revealed that the structure of composite is found to have better BN and SiC particle dispersion and uniformity. The 5 percentage in weight (wt%) of BN and 5 wt% of SiC facilitated better tensile strength (183 MPa), hardness (85HV), and impact strength (21.4J/mm2) behaviour, which are 26, 30, and 35% better than the monolithic AZ91D alloy. This AZ91D/5wt% BN and 5wt% SiC hybrid composite is involved in automotive top roof frame applications.
Venkatesh, R., Kaliyaperumal, Gopal, Manivannan, S., Karthikeyan, S., Mohanavel, Vinayagam, Soudagar, Manzoore Elahi Mohammad, Karthikeyan, N.
Cracking Activity and Characterization of Magnesium Titanium Dioxide - Silicon Dioxide Catalysts2024-01-524112/10/2024
Purified nickel and a large number of MgTi2 / NiO2 catalysts with various MgTi2 loadings were produced using the traditional incipient wetness method. X-ray crystallography and Fourier-transform infrared spectroscopy were used to examine the catalysts. To understand the material's microstructure better, the researchers investigated oxygen adsorption at 90K. The amine titration method was used to investigate the acidic characteristics of these catalysts. In a study on cumene cracking, these catalysts were employed. The catalyst was found to be amorphous up to a loading of 12 weight percent MgTi2, but at higher loadings, crystalline MgTi2 phase formed on an amorphous silica substrate. When NiO2 is doped with more MgTi2, there are significant differences in the structure, surface acidity, and catalytic activity of the catalysts. Catalysts with a higher MgTi2 loading are noticeably more acidic than those with a lower MgTi2 loading. A correlation between the amount of cracking activity and the number of acid sites on the catalyst surface has been shown in numerous studies. Cumene cannot be cracked over the investigated catalysts unless the catalyst contains extremely acidic sites. Unmistakably Bronsted acid sites, with the breaking action attributed to a mechanism involving chromium ions. The results were validated by comparing them with relevant studies in the existing literature. These comparisons demonstrate consistency with similar research, confirming the effectiveness of the MgTi2/NiO2 catalysts.
Ashok Kumar, B., Dhiyaneswaran, J., Selvaraj, Malathi, Pradeepkumar, M., Shajeeth, S.
Magnesium Alloy Hybrid Composite Properties are Featured with Boron Carbide Particle for Automotive Seat Frame Usage2024-01-520712/10/2024
With the advancement of lightweight magnesium-based hybrid composites, are potential for weight management applications. The liquid state stir cast process is the best way to produce complex shapes and most industries are preferred. However, the melting of magnesium alloy and achieving homogenous particle distribution are the major challenges for the conventional stir-casting process, and hot crack formation is spotted due to thermal variations. The main objectives of the present research are to enhance the microstructural and mechanical behaviour of magnesium alloy hybrid nanocomposite (AZ91E) adopted with boron carbide (B4C) and alumina (Al2O3) nanoparticles through a semisolid stir cast technique associated with inert atmosphere helps to limits the oxide formation and reduce risk of magnesium fire. The effect of composite processing and multiple reinforcements on surface morphology, tensile strength, impact strength, and hardness were thoroughly evaluated and compared. The results of surface morphology studies demonstrate homogeneous particle dispersion with reduced casting defects. Furthermore, the AZ91E alloy hybrid nanocomposite (HNC) exhibits superior tensile strength, impact strength, and hardness when compared to the monolithic AZ91E alloy, showcasing improvements of 18%, 23%, and 25%, respectively, which is suggested for automotive seat frame applications.
Manivannan, S., Venkatesh, R., Kaliyaperumal, Gopal, Karthikeyan, S., Mohanavel, Vinayagam, Soudagar, Manzoore Elahi Mohammad, Karthikeyan, N.
Study of Functional Behaviour of Cast Magnesium Alloy with Zirconium Addition2024-01-520612/10/2024
Magnesium is the lightest material than aluminium and has a better specific strength, which is utilized for weight management applications. This research developed the magnesium (Mg) matrix with 0.1, 0.2, 0.3, and 0.5 percentages in weight (wt%) of zirconium (Zr) particles (grain refinement agent) via the squeeze cast technique. The argon inert gas is limit oxidation during the melting of Mg. The influence of Zr on the functional properties of Mg is studied and related to monolithic Mg without the Zr phase. The microstructural analysis provides the Zr particles are dispersed uniformly in the Mg matrix and exposed to superior mechanical properties. The Mg processed with 0.5 wt% of Zr offered maximum hardness, ultimate tensile strength, and elongation percentage, which are 53, 48.8, and 43.5 % better than the values of monolithic Mg. Besides, the optimum Mg refining with 0.5 wt% Zr microstructure is detailed with EDS and conforms to the contribution of Zr. This is used for automotive structural (frame) applications.
Venkatesh, R., Manivannan, S., Das, A. Daniel, Mohanavel, Vinayagam, Soudagar, Manzoore Elahi Mohammad
Magnesium Alloy and Silicon Nitrides Composite Study: Synthesis and Abrasive Water Jet Machining Behavior and Optimization05-18-02-001411/15/2024
Related to traditional engineering materials, magnesium alloy-based composites have the potential for automobile applications and exhibit superior specific mechanical behavior. This study aims to synthesize the magnesium alloy (AZ61) composite configured with 0 wt%, 4 wt%, 8 wt%, and 12 wt% of silicon nitride micron particles, developed through a two-step stir-casting process under an argon environment. The synthesized cast AZ61 alloy matrix and its alloy embedded with 4 wt%, 8 wt%, and 12 wt% of Si3N4 are subjected to an abrasive water jet drilling/machining (AJWM) process under varied input sources such as the diameter of the drill (D), transverse speed rate (v), and composition of AZ61 composite sample. Influences of AJWM input sources on metal removal rate (MRR) and surface roughness (Ra) are calculated for identifying the optimum input source factors to attain the best output responses like maximum MRR and minimum Ra via analysis of variant (ANOVA) Taguchi route with L16 design approach. The ANOVA analysis revealed that D, v and the composition of AZ61 alloy composite contribute 26.45%, 16.28%, and 20.84%, respectively, to the output response conditions for higher MRR. Additionally, design 7 exhibits a high MRR of 0.017 g/s and a surface roughness (Ra) of 0.84 μm. The optimum AWJM input source of design 7 is proposed for industries to mass production applications.
Venkatesh, R.
Wear Behavior of Hard Ceramic Coatings by Aluminum Oxide– Aluminum Titanate on Magnesium Alloy2023-01-51092/23/2024
Magnesium and its alloys are promising engineering materials with broad potential applications in the automotive, aerospace, and biomedical fields. These materials are prized for their lightweight properties, impressive specific strength, and biocompatibility. However, their practical use is often hindered by their low wear and corrosion resistance. Despite their excellent mechanical properties, the high strength-to-weight ratio of magnesium alloys necessitates surface protection for many applications. In this particular study, we employed the plasma spraying technique to enhance the low corrosion resistance of the AZ91D magnesium alloy. We conducted a wear analysis on nine coated samples, each with a thickness of 6mm, to assess their tribological performance. To evaluate the surface morphology and microstructure of the dual-phase treated samples, we employed scanning electron microscopy (SEM) and X-ray diffraction (XRD). The bare AZ91D magnesium alloy exhibited a microhardness value of 403 HV. However, the coatings substantially improved these values, resulting in hardness measurements of 715 HV and 850 HV, respectively.
Kishore Kanna, K., Mohamed Thariq, R., Marimuthu, S., Daniel Das, A., Suresh Balaji, R., Manivannan, S.
The Impacts of Fly Ash Particles on the Zinc Aluminum Casting Alloy and Its Mechanical Properties2023-01-51232/23/2024
Fly ash is a light byproduct produced when pulverized coal is burnt in suspension-fueled furnaces in power plants. Separating the recovered fly ash from the exhaust gases. Due to its distinct physical and chemical properties, it is utilized in a wide variety of industrial and building applications. These applications include the production of cement and concrete, the stabilization of liquid waste, and hydraulic mining backfill. Fly ash has the potential to enhance the physical and mechanical properties of aluminum castings, as well as reduce their costs and increase their densities, all while lowering their prices. This research investigated the effect of fly ash incorporation on the mechanical properties of the aluminum casting alloy ZA8. Investigated were the cast and heat-treated varieties of unreinforced ZA8 and its metal matrix composite of 15% ferrous, 20% nickel, 10% fly ash, and 10% magnesium carbide. According to the results, the quantity of fly ash in the melt affected the tensile and impact properties of the metal matrix composite. The loss of magnesium atoms in the matrix, which contributes to the strength of solid solutions, and porosity both contribute to the lower mechanical properties and impact resistance of the metal matrix composite.
Dinesh Krishnaa, S., Pandiyan, Manikandaprabu, Ben Ruben, R., Dhiyaneswaran, J., Sanjay Kumar, S.
Exploring Stress Corrosion Cracking in Magnesium-Based Alloys Exposed to Potassium Chromate in Automotive Applications2023-01-51452/23/2024
Magnesium alloys possess a unique combination of benefits stemming from their exceptional strength-to-weight ratio and reduced density. The aforementioned attributes render them notably attractive for utilization in automotive and aeronautical sectors. Furthermore, these alloys are gaining significant interest from the industry because of their outstanding dimensional stability, excellent ability to dampen vibrations, high recyclability, and good castability. They also exhibit superior stiffness, among other attributes. Nonetheless, magnesium and its alloys face several noteworthy challenges that limit their industrial utilization. These include low resistance to deformation over time, limited stability at high temperatures, restricted malleability, poor ductility, and inadequate resistance to corrosion. This study aims to investigate the phenomenon of stress corrosion cracking in magnesium alloy when exposed to potassium chromate. Addition of Ca showed better mechanical properties. A proof ring test was conducted NaCl-K2CrO4 solution at 60% YS value of base material, shows that the AZ91+4%Ca is having the least stress corrosion resistance. Threshold stress for AZ91 with 1%, 2%, 3% wt% Ca is found to be higher than the applied stress value in both the corrosion environment, so that the material has not failed even after the test duration of 720h. The observed stress corrosion resistance in AZ91+4% Ca is unsatisfactory due to the brittle nature of the large Al2Ca phase. In contrast, AZ91 alloys containing 1%, 2%, or 3% Ca, which have a lower proportion of Al2Ca phase, exhibit improved mechanical properties and enhanced resistance to stress corrosion cracking (SCC).
Daniel Das, A., Suresh Balaji, R., Marimuthu, S., Manivannan, S.
Impact of Notch Design on the Energy Absorption Characteristics of Aluminium Magnesium 5456 Tube under Axial Impact Load2023-01-51222/23/2024
Over the years the vehicle population has drastically grown which increases the number of road accidents. The accident severity caused fatality and disability being reduced by introducing energy absorption materials (Crash tube). Over the years, researchers have used aluminium, magnesium, and titanium crash tubes to enhance the energy absorption characteristics during different crash scenarios. However crash tube will possess sufficient rigidity to absorb the impact force during collision but it is still challenging to identify the right material. At the same time, this paper aims to examine the energy absorption characteristics of Aluminium-Magnesium hybrid material (Al-Mg 5456) crash tube designs. Three designs were considered square, cylindrical, and hexagonal designs along with different notch designs to minimize the weight percentage of tubes. The LSDYNA results the oval notches performed better in energy absorption when compared to other designs. Hence, the present findings can satisfy the future needs that are required for electric vehicles and can be a leading-edge innovation in the upcoming automotive industry.
Krishnasamy, Prabu, Rajamurugan, G., Agarwal, Vyom, rai, Ritesh
Study of Corrosion Behavior of Hard Anodized Magnesium Alloy by Dow-17 Process2023-01-51762/23/2024
This study focuses on enhancing the corrosion resistance of AZ91D magnesium alloy, known for its impressive strength-to-weight ratio within the magnesium group. Despite its lightweight properties, the alloy's moderate corrosion and wear resistance have restricted its widespread use. To address this limitation, we explored the application of the Dow 17 process to enable hard anodizing of AZ91D magnesium alloy. Our primary objective is to investigate the impact of hard anodizing on AZ91D magnesium alloy and its potential to mitigate corrosion issues. Hard anodizing results in the formation of a robust oxide film on the alloy's surface. We posit that this oxide film can significantly reduce substrate corrosion, expanding the alloy's utility in various applications. To substantiate our claims, we conducted a comprehensive corrosion performance analysis of AZ91D magnesium alloy, with and without hard anodizing treatment. We employed advanced techniques, including potential dynamic polarization (PDP) and electrochemical impedance spectroscopy (EIS), to compare the corrosion behavior of treated and untreated specimens. Preliminary results suggest that the presence of a thick oxide layer resulting from hard anodizing greatly improves corrosion resistance properties. This promising outcome underscores the potential of hard anodizing as a method to enhance the corrosion resistance of AZ91D magnesium alloy, opening new possibilities for its application in diverse industrial applications. The key parameters of this research work are Coating Thickness, Anodizing Duration, Hard Anodizing Process and Surface Preparations.
Marimuthu, S., Manivannan , S., Daniel Das, A., Suresh Balaji, R., Abishek, S., Yogendra Kumar, R.
Turning Carbon Emissions into RocksTBMG-4923310/1/2023
In Penn’s Clean Energy Conversions Lab, researcher Peter Psarras and colleagues are repurposing waste from industrial mines, storing carbon pulled from the atmosphere into newly formed rock. The team sees great environmental potential in mine tailings, the sand and sludge left behind after the sought-after ore gets removed. With samples in the lab, they’re trying to determine just how much calcium and magnesium each contains, how to best carbonate it with CO2, how and where they can store the result, and whether the process is scalable.
Aluminum Alloy, Sheet and Plate 2.5Mg - 0.25Cr (5052-O) AnnealedAMS4015N (Current)6/13/2023
This specification covers an aluminum alloy in the form of sheet and plate 0.006 to 3.000 inches (0.15 to 76.20 mm), inclusive, in nominal thickness (see 8.5).
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Alclad Sheet and Plate 4.3Cu - 1.4Mg - 0.60Mn (Alclad 2524-T3) Solution Heat Treated and Cold WorkedAMS4296D (Current)5/10/2023
This specification covers an aluminum alloy in the form of sheet and plate 0.032 to 0.310 inch (0.81 to 7.87 mm), inclusive, in thickness, clad on both sides (see 8.5).
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Sheet, and Plate 6.3Cu - 0.30Mn - 0.06Ti - 0.10V - 0.18Zr Solution and Precipitation Heat Treated (2219 -T81/-T851)AMS4599B (Current)5/10/2023
This specification covers an aluminum alloy in the form of sheet and plate from 0.020 to 6.000 inches (0.51 to 152.40 mm), inclusive, in thickness (see 8.5).
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Coiled Sheet 4.4Cu - 1.5Mg - 0.60Mn (2024-T4) Solution TreatedAMS4477B (Current)5/10/2023
This specification covers an aluminum alloy in the form of coiled sheet 0.010 to 0.249 inch (0.25 to 6.32 mm), inclusive, in thickness, supplied in the -T4 temper (see 8.5).
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Sheet and Plate, Alclad 4.4Cu - 1.5Mg - 0.60Mn (Alclad 2024, -T81 Sheet, -T851 Plate) Solution Heat Treated, Cold Worked and Artificially AgedAMS4478B (Current)3/20/2023
This specification covers an aluminum alloy in the form of Alclad sheet and plate 0.010 to 0.499 inch (0.254 to 12.67 mm), inclusive, in thickness, supplied in the -T81/-T851 temper (see 8.5).
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Sheet and Plate 5.6Zn - 2.5Mg - 1.6Cu - 0.23Cr Annealed (7075-O) or, When Specified, “As Fabricated” (7075-F)AMS4044P (Current)2/20/2023
This specification covers an aluminum alloy in the form of sheet and plate from 0.008 to 2.000 inches (0.20 to 50.80 mm), inclusive, in thickness, supplied in the annealed (O) condition (see 8.5).
AMS D Nonferrous Alloys Committee
Optimizing the Tribological Process Parameters of Calcium Hexaboride Reinforced Magnesium Composite Using Grey Relational Analysis2022-28-056712/23/2022
Different weight percentages (0, 1 and 2 wt. %) of Calcium hexaboride (CaB6) is reinforced with pure magnesium and the composite is fabricated through powder metallurgy technique. The fabricated samples are used for the tribological evaluation. In this connection, the Taguchi optimization technique (L27 Orthogonal array) assisted Grey Relational analysis is used for predicting the significant factors to the tribological evaluation. The magnesium composite wear rate is evaluated by Archard’s mass loss method. Based on the obtained results, it is observed that the magnesium composite wear rate is increased by the effect of an increase in load. It was arising as a result of enhanced delamination wear mechanism which is confirmed by SEM observation on the worn-out pin surface.
K, Kaviyarasan, Parasuraman, Seenuvasaperumal, Ayyasamy, Elayaperumal, Murphin Kumar, Paskalis Sahaya
Electrolytic Treatment for Magnesium Alloys Alkaline Type, Full CoatAMS2476D (Current)11/22/2022
This specification establishes the engineering requirements for producing anodic coatings on magnesium and magnesium alloys, from an alkaline electrolyte, and the properties of those coatings.
AMS B Finishes Processes and Fluids Committee
Effect of Solutionising on Change in Phase Morphology, Mechanical Behavior & Corrosion Behavior for AZ Series as Cast Automotive Magnesium Alloy Components2022-28-005810/5/2022
Magnesium is sought to be one of the futuristic material in automotive due to its superior properties such as density, strength to weight ratio, damping characteristics and thus, making it a key enabler for light weighting. The properties of Magnesium alloys can be widely altered by change in elemental composition and heat treatment. Analysis of composition and phase morphology are driving factors for determining component’s end use properties and can be utilized effectively in its product development cycle. The as-cast AZ series alloys develop microstructure consisting of α-Mg matrix, eutectic α-Mg/γ-Mg17Al12 phase with non-uniform Al solute content in the α-Mg. Solutionising causes dissolution of Mg17Al12 brittle phase thereby increasing strength and ductility in these alloys. This paper presents analysis of AZ series automotive alloy components with focus on microstructure and mechanical properties change after solutionising. Scanning electron microscopy & energy dispersive spectroscopy techniques are adopted to evaluate phase changes along with morphology which affected properties after solutionising. Corrosion behaviour of AZ91 in as cast, solutionized and solutionized & aged condition is also studied.
Manwatkar, Asmita Ashok, Deshmukh, Prasanna Bhagwan, Setia, Shivam, Phale, Prasad Sitakant, Santosh Jambhale, Medha
Aluminum Alloy Sheet, 2.7Cu - 2.2Li - 0.12Zr (2090-T83), Solution Heat Treated, Cold Worked, and Precipitation Heat TreatedAMS4251C (Historical)9/8/2022
This specification covers an aluminum alloy in the form of sheet 0.040 to 0.249 inch (1.02 to 6.32 mm) in nominal thickness (see 8.7).
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Sheet and Plate 6.3Cu - 0.30Mn - 0.18Zr - 0.10V - 0.06Ti (2219-O) Annealed or, When Specified, “As Fabricated” (2219-F)AMS4031K (Current)8/17/2022
This specification covers an aluminum alloy in the form of sheet and plate 0.020 to 2.000 inches (0.51 to 50.80 mm), inclusive, in nominal thickness, supplied in the annealed (-O) condition (see 8.3). When specified, product shall be supplied in the “as fabricated” (-F) temper.
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Sheet and Plate (2014; -T6 Sheet, -T651 Plate) Solution and Precipitation Heat TreatedAMS4029M (Current)8/17/2022
This specification covers an aluminum alloy in the form of sheet and plate 0.020 to 4.00 inches (0.51 to 101.60 mm), inclusive, in nominal thickness (see 8.5).
AMS D Nonferrous Alloys Committee
Aluminum Alloy Sheet and Plate, Alclad 5.6Zn - 2.5Mg - 1.6Cu - 0.23Cr (Alclad 7075-O) Annealed or when specified, “As Fabricated” (Alclad 7075-F)AMS4048R (Current)8/5/2022
This specification covers an aluminum alloy in the form of sheet and plate 0.008 to 1.000 inch (0.20 to 25.40 mm), inclusive, in thickness, clad on two sides, supplied in the annealed (O) condition. When specified, product shall be supplied in the “as fabricated” (F) temper (see 8.6).
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Sheet and Plate, Alclad 5.6Zn - 2.5Mg - 1.6Cu - 0.23Cr (Alclad 7075; -T6 Sheet - T651 Plate) Solution and Precipitation Heat TreatedAMS4049N (Current)8/5/2022
This specification covers an aluminum alloy in the form of sheet and plate with thickness from 0.008 to 4.000 inches (0.20 to 101.6 mm), inclusive, clad on two sides (see 8.6).
AMS D Nonferrous Alloys Committee
Aluminum Alloy Sheet and Plate 5.6Zn - 2.5Mg - 1.6Cu - 0.23Cr 7075: (-T6 Sheet, -T651 Plate) Solution and Precipitation Heat TreatedAMS4045M (Current)8/5/2022
This specification covers an aluminum alloy in the form of sheet and plate 0.008 to 4.000 inches (0.20 to 101.6 mm), inclusive, in thickness (see 8.6).
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Alclad Sheet 4.4Cu - 1.5Mg - 0.60Mn (2024-T4 Flat Sheet) Solution Heat Treated, High FormabilityAMS4279C (Current)8/5/2022
This specification covers an aluminum alloy in the form of sheet clad on both sides with a different alloy for sheet thicknesses of 0.020 to 0.128 inches (0.51 to 3.25 mm), inclusive, in nominal thickness (see 8.5).
AMS D Nonferrous Alloys Committee
Aluminum Alloy Sheet and Plate 4.4Cu - 0.85Si - 0.80Mn - 0.50Mg (2014-O) AnnealedAMS4028J (Current)7/6/2022
This specification covers an aluminum alloy in the form of sheet and plate from 0.020 to 1.000 inch (0.51 to 25.4 mm) thick (see 8.6).
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Plate (2098-O) 3.5Cu - 1.1Li - 0.50Mg - 0.40Ag - 0.11Zr AnnealedAMS4327B (Current)6/2/2022
This specification covers an aluminum alloy in the form of plate 0.250 to 0.300 inch (6.35 to 7.62 mm), inclusive, in thickness (see 8.8).
AMS D Nonferrous Alloys Committee
Aluminum Alloy Plate (2027-T351) 4.4Cu - 1.2Mg - 0.8Mn - 0.10Zr Solution Heat Treated, Cold Worked and Naturally AgedAMS4213B (Current)6/2/2022
This specification covers an aluminum alloy in the form of plate 0.500 inches (12.7 mm) to 2.250 inches (57.2 mm) in nominal thickness (see 8.6).
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Sheet and Plate 1.0Mg - 0.60Si - 0.28Cu - 0.20Cr (6061; -T6 Sheet, -T651 Plate) Solution and Precipitation Heat TreatedAMS4027P (Current)4/29/2022
This specification covers an aluminum alloy in the form of sheet and plate from 0.006 to 6.000 inches (0.15 to 152.40 mm), inclusive, in nominal thickness (see 8.6).
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Drawn, Round Seamless Tubing 6.3Cu - 0.30Mn - 0.18Zr - 0.10V - 0.06Ti - (2219-T8511) Solution Heat Treated, Stress Relieved by Stretching and Precipitation Heat TreatedAMS4066D (Current)4/29/2022
This specification covers an aluminum alloy in the form of drawn, round seamless tubing 0.500 inch (12.70 mm) and over in OD with nominal wall thickness of 0.029 to 0.500 inch (0.74 to 12.70 mm) (see 8.6).
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Extruded Round Rod 3.5Cu - 1.0Li - 0.40Mg - 0.45Ag - 0.12Zr (2050-T84) Solution Heat Treated, Stress Relieved by Stretching, and Artificially AgedAMS4353A (Current)4/22/2022
This specification covers an aluminum alloy in the form of extruded round rods.
AMS D Nonferrous Alloys Committee
Padded Self-Piercing Riveting (P-SPR) on Magnesium High Pressure Die Casting2022-01-02493/29/2022
Padded self-piercing riveting (P-SPR) is a newly developed multi-material joining technology to enable less ductile materials to be joined by self-piercing riveting (SPR) without cracking. A deformable and disposable pad was employed to reduce the stress distribution on the bottom surface by supporting the whole bottom sheet continuously during rivet setting process. To verify the P-SPR process, 2.0mm thick 6061-T6 wrought aluminum was joined with 3.2mm thick coated AM60B magnesium high pressure die casting (HPDC) by using 1.0mm thick dual-phase 600 (DP600) steel as the pad. Regular SPR processes with 2 different die geometries were studied as a comparison. Compared to the regular SPR processes, P-SPR demonstrated advantages on coating protection, crack mitigation and joint strength.
Liu, Yuchao, Wang, Gerry, Weiler, Jonathan
Low-Cost Magnesium Alloy Sheet Component Development and Demonstration Project2022-01-02483/29/2022
Most of the applications of magnesium in lightweighting commercial cars and trucks are die castings rather than sheet metal, and automotive applications of magnesium sheet have typically been experimental or low-volume serial production. The overarching objective of this collaborative research project organized by the United States Automotive Materials Partnership (USAMP) was to develop new low-cost magnesium alloys, and demonstrate warm-stamping of magnesium sheet inner and outer door panels for a 2013 MY Ford Fusion at a fully accounted integrated component cost increase over conventional steel stamped components of no more than $2.50/lb. saved ($5.50/kg saved). The project demonstrated the computational design of new magnesium (Mg) alloys from atomistic levels, cast new experimental alloy ingots and explored thermomechanical rolling processes to produce thin Mg sheet of desired textures. A new commercial Mg alloy sheet material was sourced and pretreated with protective coil coatings, and its properties fully characterized. The Mg sheet was successfully warm-formed using novel lubricants into intermediate size benchmark parts and full-size automotive door inner and outer panels. The project also explored conventional welding processes for joining of Mg sheet, developed novel corrosion treatments for multi-metal assembly coatings, performed computer simulations of door panel forming using two new material cards based on crystal plasticity theory, and concluded with a door static and dynamic performance analysis. An overall cost driver and sensitivity assessment task compared the final cost penalty depending on the cost of the primary magnesium sheet.
Gerken, Randy T., Ghaffari, Bita, Sachdev, Anil K., Mehta, Manish, Carter, Jon T.
Aluminum Alloy Sheet, Alclad 6.0Cu - 0.40Zr - (2004-F) As RolledAMS4209D (Current)2/1/2022
This specification covers an aluminum alloy in the form of clad sheet, less than 0.250 inches (6.35 mm) thick.
AMS D Nonferrous Alloys Committee
Smart Wound Dressings with Built-In Healing SensorsTBMG-405561/1/2022
Multifunctional antimicrobial dressings were developed that feature fluorescent sensors that glow brightly under UV light if infection starts to set in and can be used to monitor the healing progress. The smart dressings harness the powerful antibacterial and antifungal properties of magnesium hydroxide.
Aluminum Alloy, Wire 5.0Mg - 0.12Mn - 0.12Cr (5056-O) AnnealedAMS4182J (Current)12/13/2021
This specification covers an aluminum alloy in the form of wire (see 8.7).
AMS D Nonferrous Alloys Committee
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