Overview
The main objective of DIMAG project was to develop and produce a magnesium Demonstrator for aircraft after answering all given aviation criteria and requirements. By achieving this objective, DIMAG facilitated obtaining the Clean Sky objectives of reduction in weight, fuel consumption, emissions of CO2 and NOX and the use of fully recyclable material. Since magnesium is 100% recyclable and is 35% lighter than aluminium, a replacement of aluminium parts with magnesium parts contributed to all the above-mentioned goals.
The main idea to be reflected in the work program was the use of several magnesium forming and surface treatment technologies, which successfully implemented on conventional alloys (i.e. AZ31, AZ80, etc.), but for new options of chemical compositions, especially for alloys with rare earth (RE) elements (such as WE43).
The project activity used drawing and bending techniques, including riveting, and surface protection processes which should be chrome-free provided, while using the above-mentioned new magnesium alloys.
The work plan was divided into three work packages: each deals with a particular type of process. The processes was examined according to technological Demonstrators offered by the ITD topic leader - a Shelf Removal Assy – Radio Rack.
The project's work plan was broken down into the following work packages:
- Deep drawing and bending of WE43 magnesium sheet;
- Joining of magnesium sheets, by mechanical riveting, including the examination of bi-metal galvanic effect (since rivets are usually made of aluminium alloy);
- Cleaning and finishing solutions applied on WE43 and other special magnesium alloys.
Funding
Results
Executive Summary:
The main objective of DIMAG project was to evaluate the option to use the new high strength magnesium alloy Elektron 43, for some sheet forming applications. The selected application - Removable Shelf (part of the Radio Rack section) - which was chosen by Israeli Aerospace Industries (IAI) Commercial Aircraft Division, as a technology demonstrator, was successfully manufactured by the M&P Department of Aero-Magnesium. It seemed that the project results proved the applicability of the advanced magnesium alloy in future aero-structures.