AEROMAG - Aeronautical Application of Wrought Magnesium
Overview
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.
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