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TRIMIS

Aeronautical Application of Wrought Magnesium

PROJECTS
Funding
European
European Union
Duration
-
Status
Complete with results
Geo-spatial type
Infrastructure Node
Total project cost
€4 034 660
EU Contribution
€2 594 327
Project Acronym
AEROMAG
STRIA Roadmaps
Vehicle design and manufacturing (VDM)
Transport mode
Airborne icon
Transport policies
Environmental/Emissions aspects,
Societal/Economic issues
Transport sectors
Passenger transport,
Freight transport

Overview

Call for proposal
FP6-2003-AERO-1
Link to CORDIS
Background & Policy context

The aluminium alloys used today for aerospace applications are already optimised as far as aeronautical requirements are concerned, such as strength, fatigue and damage tolerance properties. Magnesium, with a density of only 65% of that of aluminium, could be a breakthrough technology in the aerospace industry if used for cost-efficient, low-weight components and airframe structures. However, to use this low weight material the mechanical and technological properties have to be improved.

Objectives

The strategic objectives were to increase the operational capacity by10%, a reduction in the direct operating cost of 10% and finally a reduction in the fuel consumption of 10% and therefore a reduced environmental impact.

The technological objectives were:

  • Weight reduction of single components up to 35 % compared to Al components
  • Higher specific mechanical properties compared to Al
  • Cost efficient processes for manufacturing of Mg products
  • Solve the possible 'flammability problem' with Mg (FAR/JAR)
  • Environmentally friendly surface protection for Mg and evaluation of corrosion behavior
  • Investigation of technologies com. used in aeronautic industry
  • Development of material models and failure criteria
  • Process simulation of forming processes
  • Manufacturing and testing of structural elements
  • Preparation of the qualification of Mg for aerospace applications
Methodology

Magnesium with a density of only 65% of aluminium, could be a breakthrough technology in the aerospace industry if used for cost efficient, low weight components and airframe structures. However, to use this low weight material the mechanical and technological properties have to be improved.

The technical focus of the university-driven project, AEROMAG, which was prepared in close collaboration with the Network of Universities 'EASN', is the development of new magnesium wrought products (sheets and extrusions), which provide significantly improved static and fatigue strength properties. The strength properties of these innovative materials are required to be as high as AA5083 for non-structural applications and as high as AA2024 for aluminium alloys for secondary structure applications.

At first new alloys were developed and existing alloys were tested. Appropriate manufacturing (rolling, extrusion), forming and joining technologies required development, simulation and validation for the innovative material and application. Corrosion is a problem that had to be solved with the newly adapted and environmentally friendly surface protection systems and advanced design concepts. Flammability was addressed with the addition of chemical elements and special surface treatments. A further essential task was the development of material models and failure criteria for the prediction of forming processes, plastic deformation and failure behaviour of components. Finally, material-adapted design and the evaluation of structural behaviour were investigated to close the process and development chain for aeronautic components.

Funding

Parent Programmes
Institution Type
Public institution
Institution Name
European Commission
Type of funding
Public (EU)

Results

Main Project Conclusions:

  • Several product forms and alloys are available; ρ=1.7-1.9 g/cm3
  • Advanced alloys with good mechanical/technological properties
  • More than 33 % increase in specific strength possible
  • HT alloys are applicable until 200°C
  • Fatigue strength (Kt=1.0, R=0.1) in rage of 150 - 220 MPa
  • Flammability tests and test definition has been initiated by AEROMAG
  • Partners with FAA; Full scale test is under progress at FAA
  • Intrinsic corrosion behavior of alloys has improved; RE based alloys
  • Show in general better corrosion behavior than AlZn systems
  • Green surface protection systems are evaluated, dep. alloys
  • Forming is possible, under elevated temperatures
  • FSW and LBW works well and results in good properties
  • Buckling behavior of stiffened panels is comparable to aluminum
  • FCP & DT behavior of 2024 T3 can not be fully reached by Mg

Magnesium wrought products are certainly applicable as low weight aeronautic applications.

Technical Implications

Opposite to common opinion about a 'non-metallic' aeronautic future, major European aerospace industries are seriously investigating magnesium as weight-reduction alternative to aluminum.

New high-strength alloys, advanced surface treatment technologies and a correct understanding of 'magnesium flammability' form the basis for magnesium comeback in aerospace industry.

10-15% of magnesium components in civil aircraft in 2015-2020 look like a real target.

Partners

Lead Organisation
Organisation
Eads Deutschland Gmbh
Address
Willy- Messerschmitt- Strasse, OTTOBRUNN, Germany
Organisation website
Partner Organisations
Organisation
Technion - Israel Institute Of Technology
Address
Senate Building Technion City, Haifa 32000, Israel
EU Contribution
€0
Organisation
Alenia Aermacchi Spa
Address
Viale Dell'aeronautica Snc, 80038 Pomigliano D'arco (Na), Italy
Organisation website
EU Contribution
€0
Organisation
Vienna University Of Technology
Address
Karlsplatz 13, WIEN, Austria
Organisation website
EU Contribution
€0
Organisation
Eads Ccr
Address
37, Boulevard de Montmorency, PARIS, France
Organisation website
EU Contribution
€0
Organisation
All-Russia Institute Of Light Alloys
Address
Gorbunov Street 2, MOSCOW, Russia
EU Contribution
€0
Organisation
Institut National Polytechnique De Grenoble
Address
46 Avenue Félix Viallet, GRENOBLE, France
Organisation website
EU Contribution
€0
Organisation
Ecole Nationale Superieure D'arts Et Metiers, Centre D'enseignement Et De Recherche D'aix En Provence
Address
2, cours des Arts et Métiers, AIX EN PROVENCE, France
Organisation website
EU Contribution
€0
Organisation
Salzgitter Magnesium-Technologie Gmbh
Address
Eisenhuettenstrasse 99, 26 SZMT SALZGITTER, Germany
Organisation website
EU Contribution
€0
Organisation
Alonim Holdings Agricultural Cooperative Ltd
Address
Kibbutz Alonim, KIBBUTZ ALONIM, Israel
EU Contribution
€0
Organisation
Palbam Metal Works
Address
Kibbutz En Harod Ihud, KIBBUTZ EN HAROD IHUD, Israel
EU Contribution
€0
Organisation
Federal State Unitary Enterprise "all-Russian Scientific-Research Institute Of Aviation Materials"
Address
Radio Street, 17, MOSCOW, 105005, Russia
Organisation website
EU Contribution
€0
Organisation
University Of Napoli Federico Ii
Address
Piazzale Tecchio 80, NAPOLI, Italy
Organisation website
EU Contribution
€0
Organisation
Otto Fuchs Kg
Address
Derschlager Strasse 26, 1261 MEINERZHAGEN, Germany
Organisation website
EU Contribution
€0
Organisation
Eurocopter
Address
Aéroport International Marseille-Provence, BP 13 MARIGNANE, France
Organisation website
EU Contribution
€0
Organisation
Laboratory Of Technology And Strength Of Materials - University Of Patras
Address
Panepistimioupolis Rion, 26500 PATRAS, Greece
Organisation website
EU Contribution
€0
Organisation
University Of Thessally - Dept Of Civil Engineering
Address
Pedion Areos, VOLOS, Greece
Organisation website
EU Contribution
€0
Organisation
Smw Engineering Ltd.
Address
Nekrasova st. 29-58, ST PETERSBURG, Russia
Organisation website
EU Contribution
€0
Organisation
Magnesium Elektron A Division Of Magnesium Elektron Limited
Address
Rake Lane, SWINTON, MANCHESTER, United Kingdom
Organisation website
EU Contribution
€0
Organisation
Airbus Deutschland Gmbh
Address
Kreetslag 10, 950109 HAMBURG, Germany
Organisation website
EU Contribution
€0
Organisation
Eads Ccr
Address
37, Boulevard de Montmorency, PARIS, France
Organisation website
EU Contribution
€0

Technologies

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