Magnesium Technology

2015

144th Annual Meeting & Exhibition March 15-19, 2015 • Walt Disney World • Orlando, Florida, USA

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Magnesium Technology

2015 Proceedings of a symposium sponsored by

Magnesium Committee of the Light Metals Division of

The Minerals, Metals & Materials Society (TMS)

held during

TIMIS2015 144th Annual Meet ing & Exhibit ion

March 15-19, 2015 Walt Disney World • Orlando, Florida, USA

Edited by: Michele V. Manuel • Alok Singh

Martyn Alderman • Neale R. Neelameggham

W l LEY TIMIS

Copyright © 2015 by The Minerals, Metals & Materials Society. All rights reserved.

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TABLE OF CONTENTS Magnesium Technology 2015

Preface xi About the Editors xiii Session Chairs xix Reviewer Pool xxi

Keynote Session

Reducing Weight for Transportation Applications: Technology Challenges and Opportunities 3 A. Taub

The Application of Magnesium Alloys in Aircraft Interiors - Changing the Rules 5 B. Davis

Emerging Science and Research Opportunities for Metals and Metallic Nanostructures: A Report on the NSF MMN Workshop 7

T. Pollock and C. Handwerker

Solute Segregation and Aggregation in Mg Alloys 9 J. Nie, Y. Zhu, and N. Wilson

Elevated Temperature and Creep Three Decades of Electron Backscatter Diffraction of Magnesium: What Has It Taught Us? 13

M. Barnett

Measuring and Modeling the Effects of Mechanical Twinning on the Behavior of Magnesium Alloys 15 S. Agnew, P. Wu, K. Inal, H. Kadiri, J. Wang, and C. Tome

Microstructure and Properties of Aged vs Crept Mg-Al-Zn-Sn Alloys with Additions of Nd and Ce 19 U. Vainberg, S. Avraham, A. Katsman, andM. Bamberger

Hot Compression Behavior of Magnesium Alloys ZE20 and AM30 25 S. Sutton and A. Luo

Creep Deformation Mechanisms and Related Microstucture Development of AZ31 Magnesium Alloy 29 P. Roodposhti, A. Sarkar, and K. Murty

Creep Response of a Zn Containing Mg-Nd-La Alloy 35 D. Choudhuri, D. Jaeger, S. Srivilliputhur, M. Gibson, and R. Banerjee

Primary, Sustainability, Recycling and Processing Thermal Electrolytic Production of Mg from MgO: Reflections on Commercial Viability 43

R. Palumbo, M. Korenko, C. Larson, L. Venstrom, S. Duncan, S. Nudehi, J. Schoer, J. Toberman, W. Prusinksi, D. Johnson, B. Robbinson, S. Barkely, K. Warren, R. Diver, F. Simko, andM. Boca

Study on Compressive Strength of Pellets for the Novel Silicothermic Process 49 D. Fu, L. Guan, M. Wen, Z. Dou, R. Zhang, and T. Zhang

Carbothermal Production of Magnesium in Vacuum 55 T. Qu, B. Yang, Y. Tian, and Y. Dai

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Effect of Argon Flow Rate on the Condensation of Magnesium Vapor from Carbothermic Reduction of Magnesia 61 G. Bin, Y. Wang, S. Wang, andX. Liang

Environmental Impact of Magnesium Production by Carbothermic Reduction in Vacuum 67 H. Liu, Y. Tian, B. Yang, B. Xu, D. Liu, and Y. Dai

Comparative Environmental Benefits of Lightweight Design in the Automotive Sector: The Case Study of Recycled Magnesium against CFRP and Steel 73

F. D 'Errico and L. Ranza

In Situ Synchrotron Radiation Diffraction during Solidification of Mgl5Gd: Effect of Cooling Rate 79 G. Szakács, C. Mendis, D. Tolnai, A. Stark, N. Schell, H. Ovri, M. Wolff, K. Kainer, J. Gröbner, R. Schmid-Fetzer, and N. Hort

Microstructures and Tensile Properties of Mg-4Al-4La-0.4Mn-XB (X = 0, 0.01, 0.02, 0.03) Alloy 85 J. Meng, Q. Yang, Z. Tian, X Qiu, and F. Meng

The Role of Bismuth in Grain Refinement of Magnesium and Its Alloys 91 U. Joshi and N. Babu

Deformation I In Situ Neutron Diffraction Study of the Deformation Mechanisms in Solutionized Mg-Zn Alloys 97

R. Mulay, S. Agnew, and C. Caceres

Investigation of Compression Behavior of Mg-4Zn-2(Nd,Gd)-0.5Zr at 350°C by In Situ Synchrotron Radiation Diffraction 103

R. Buzolin, D. Tolnai, C. Mendis, A. Stark, N. Schell, H. Pinto, K. Kainer, and N. Hort

The Deformation Behavior, Micro structure and Mechanical Properties of Cast and Extruded Mg-lMn-xNd (wt%) at Temperatures between 50 C and 250 C 109

A. Chakkedath, J. Bohlen, S. Yi, D. Letzig, Z. Chen, and C. Boehlert

Effect of Dynamic Strain Aging on the Strain Rate Sensitivity of a Mg-2Zn-2Nd Alloy 115 T. Wang, S. Yue, and J. Jonas

The Deformation Gradient of Interfacial Defects on Twin-Like Interfaces 121 C. Barrett and H. El Kadiri

Geometrically Necessary Twins in Bending of an AZ31 Sheet 127 B. Li, Z. McClelland, and S. Horstemeyer

Deformation Twinning Effects on Texture and Microstructure of AZ3 IB Magnesium Rolled Samples 133 L. Catorceno, L. Herculano, andH. deAbreu

Dislocation-Twin Interactions in Magnesium Alloy AZ31 139 F. Wang and S. Agnew

Role of Tensile Twinning on Fracture Behavior of Magnesium AZ31 Alloy 145 S. Narla, R. Narasimhan, and S. Suwas

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Deformation II New Model Predicting the Unusual Buckling Behavior of AZ31 Mg 153

N. Chandola, O. Cazacu, and B. Revil-Baudard

Why Do Magnesium Alloys Develop Sharp Textures upon Dynamic Recrystallization? 159 H. El Kadiri, C. Barrett, A. Imandoust, S. Agnew, M. Cherkaoui, and K. Inal

Crystal Plasticity Modeling of the Dynamic Behavior of Magnesium Alloy, WE43-T5, Plate 165 J. Bhattacharyya, S. Agnew, P. Wu, W. Wittington, and H. El Kadiri

Micro mechanical Modeling of Evolving Anisotropy in AZ31 Mg for Various Strain Paths 171 N. Chandola, O. Cazacu, and R. Mishra

Recrystallization Behavior of the Magnesium Alloy ZE20 177 X Ma, Z. Huang, M. Li, and J. Allison

Ballistic Characterization of the Scalability of Mg Alloy AMX602 183 T. Jones, K. Kondoh, D. Moore, L. Otsuka, A. Annis, H. Nakazawa, Y. Ohori, R. Numasawa, andM. Takahashi

Deformation Response of Mg-Y Alloys under Dynamic Loading 189 T. Mukai, M. Nagao, T. Terada, H. Somekawa, and A. Singh

Large Strain Behaviour of ZEK100 Magnesium Alloy at Various Strain Rates 191 J. Lévesque, S. Kurukuri, R. Mishra, M. Worswick, and K. Lnal

Effect of Solute Segregation on Fracture Behavior of Mg Alloy 197 T. Kawa, M. Yamaguchi, N. Lkeo, and T. Mukai

Wrought Development of Thin-Walled Magnesium Alloy Extrusions for Improved Crash Performance Based upon Texture Control 203

B. Williams, S. Agnew, R. Klein, and J. McKinley

Role of Zr in the Microstructure Evolution in Mg-Zn-Zr Based Wrought Alloys 209 T. Bhattacharjee, T. Sasaki, B. Suh, T. Nakata, S. Kamado, N. Kim, and K. Hono

Effect of Alloy Composition on Microstructure and Strength of Fine Grained Extruded Mg-Zn-Y Alloys Containing Quasicrystal Phase 215

A. Singh, Y. Osawa, H. Somekawa, T. Mukai, C. Parrish, and D. Shih

An Extruded and Peak Aged Mg-5Gd-3Y-lZn-Zr Alloy with High Strength 221 D. Wu, J. Li, M. Hong, W. Wang, R. Chen, E. Han, and W. Ke

Strengthening in Thermomechanically Processed Magnesium Alloys 225 B. Mansoor, R. Decker, and S. LeBeau

Microstructures and Mechanical Properties of Mg-lat%X Alloys Processed with High-Pressure Torsion 231 H. Kawabata, S. Kuramoto, and K. Oh-ishi

Dependence of Compression-Tension Loading on Twinning in Wrought Mg Alloy 237 D. Drozdenko, J. Bohlen, S. Yi, D. Letzig, F. Chmelik, and P. Dobroñ

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Effect of Mn Content on Micro structures and Mechanical Properties of Mg-Al-Ca-Mn Alloys Fabricated by High-Speed Extrusion

T. Nakata, K. Shimizu, Y. Matsumoto, S. Hanaki, and S. Kamado 241

Effects of Extrusion Processing and Heat Treatment on Mechanical Property and Heat Dissipation Performance of Mg-2.5Nd-l.0Zn-0.5Zr Alloy 247

J. Wang, J. Zhang, G. Wu, and W. Peng

Forming and Alloy Design Effect of Initial Microstructures on Cold-Rollability of RE-Free Magnesium Alloys 253

Y. Kim, S. Jo, and B. You

Studies on the Magnesium Alloys Cladding in the Plastic Forming Processes (Die Forging and Extrusion) Using as the Clad Layer Corrosion Resistant Aluminum Alloys 257

P. Korczak, B. Plonka, D. Lesniak, M. Nowak, K Remsak, and S. Boczkal

The Effects of Plastic Anisotropy in Warm and Hot Forming of Magnesium Sheet Materials 263 E.. Taleff, A. Antoniswamy, A. Carpenter, andE. Yavuz

Effect of Heat Treatment on Micro structure and Damping Capacity of Twin Roll Cast ZK60 Strip 267 H. Chen, Q. Zang, J. Zhang, J. Cho, Y. Jin, and Y. Shi

Deformation Behavior of Rolled Magnesium Slabs and Twin Roll Cast Strips Studied by the Acoustic Emission Technique 273

P. Dobroh, D. Drozdenko, J. Bohlen, D. Letzig, and F. Chmelik

Effects of Texture and Alloying Elements on Stretch Formability of Mg Alloy Sheets 277 B. Suh, J. Kim, J. Bae, and N. Kim

Progress in Thermodynamic Database Development for ICME of Mg Alloys 283 R. Schmid-Fetzer

Simulation of Concurrent Precipitation of Two Strengthening Phases in Magnesium Alloys 289 W. Sun, C. Zhang, A. Klarner, W. Cao, and A. Luo

Strengthening Mechanisms in M g g y Z n ^ Alloys 295 Z. Yang and H. Ye

Corrosion, Coatings, Fatigue, and Fracture Fatigue and Corrosion Fatigue of Cold Drawn WE43 Wires 303

A. Griebel and J. Schaffer

Deformation and Failure Modes of Rapidly Solidified, Ultra-Fine Grain, AMX602 and ZAXE1711 Magnesium Alloys 309

J. Chinella

Effect of Sn:Zn Ratio on Corrosion Behavior of Mg-aSn-bZn Extrusions 315 C. Yim, S. Woo, and B. You

Stress Corrosion Cracking of ZEK100 Magnesium Alloy for Automotive Applications 319 X Pang, C. Shi, and R. Zavadil

Effect of Ca and Y on Corrosion Behavior of Extruded AZ Series Mg Alloys 323 X Woo, C. Yim, Y Kim, and B. You

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Characterization of Coatings on Steel Self-Piercing Rivets for Use with Magnesium Alloys 327 R. McCune, J. Forsmark, V. Upadhyay, and D. Battocchi

Investigation of Coating and Corrosion Mitigation Strategies in Magnesium/Mixed Metal Assemblies 333 J. Forsmark, R. McCune, T. Giles, M. Audette, J. Snowden, J. Stalker, M. Morey, M. O'Keefe, and C. Castano

Influence of Pulse Time on the Structural and Tribological Properties of Micro Arc Oxidized AZ91D Magnesium Alloy 339

D. Kilic, F. Muhaffel, Y. Yurekturk, and M. Baydogan

Electroless Ni-P/Nano-Si02 Composite Plating on Dual Phase Magnesium-Lithium Alloy 343 Y. Zou, Z. Zhang, and M. Zhang

Casting and Metal Matrix Composites Process-Structure-Property Correlations forHPDC AM60B 351

P. Sharifi, Y. Fan, K. Sadayappan, G. Birsan, and J. Wood

Influence of Alloy Composition on Cast Cracking and Heat Resistance of Mg-Al-Ca Cast Alloy 357 H. Kato, H. Kawabata, S. Inoue, andM. Kondo

Microstructural Scale Effects on Thermal Expansion Behaviour of Cast AZ91D 361 H. Dini, N. Andersson, E. Ghassemali, and A. Jarfors

Precipitation Sequence in a Mg-Sm-Zn-Zr Alloy 367 X Xia, A. Sanaty-Zadeh, R. Chen, X. Zeng, A. Luo, and D. Stone

The Exomet Project: EU/ESA Research on High-Performance Light-Metal Alloys and Nanocomposites 373 W. Sillekens

Phase Evaluation of Sr and CaO Added Mg-Al-Si Alloys 377 Y. Jung, Y. Yoon, S. Kim, H. Lim, and D. Kim

High Performance Mg6Zn Nanocomposites Fabricated through Friction Stir Processing 383 J. Xu, C. Cao, S. Das, L. Chen, C. Ma, R. Mishra, andX. Li

Synthesis and Characterization of Novel Magnesium Materials Containing Copper-Titanium Based (Cu50Ti50) Amorphous Alloy Particles 387

S. Sankaranarayanan, N. Agrawal, S. Jayalakshmi, Q. Nguyen, and M. Gupta

Biomedical Applications Mechanical and Corrosive Properties of Two Magnesium Wires: Mg4Gd and Mg6Ag 393

P. Maier, G. Szakacs, M. Wala, and N. Hort

Degradation Behavior of Mg-Ca Nail after Penetration into Artificial Bone 399 N. Lkeo, J. Shimizu, C. Lshigaki, Y. Sano, Y. Shimizu, and T. Mukai

Improving the Corrosion Resistance of Biodegradable Magnesium Alloys by Diffusion Coating Process 403 G. Levy and E. Aghion

Effects of Heat Treatment on Bio-Corrosion Properties of Mg-Zn-xMn (x= 0.5, 1.0, and 1.5 wt.%) Alloys as Biodegradable Materials 407

W. Yang, Y. Yoon, S. Kim, H. Lim, and D. Kim

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Effects of Ti and TiB2 Nanoparticulates on Room Temperature Mechanical Properties and In Vitro Degradation of Pure Mg 413

G. Meenashisundaram, M. Nai, and M. Gupta

Microstructure and Properties of Magnesium Alloy Mg-lZn-ICa (ZX11) 419 L. Katsarou, K. Suresh, K. Rao, N. Hort, C. Blawert, C. Mendis, and H. Dieringa

Powder Metallurgical Synthesis of Biodegradable Mg-Hydroxyapatite Composites for Biomedical Applications 425

C. Stüpp, G. Szakács, C. Mendis, F. Gensch, S. Müller, F. Feyerabend, D. Hotza, M. Fredel, and N. Hort

Correlation between Mechanical Behaviour and Microstructure in the Mg-Ca-Si-Sr System for Degradable Biomaterials Based on Thermodynamic Calculations 431

A. Gil-Santos, G. Szakacs, N. Moelans, N. Hort, and O. Van der Biest

Investigation of Al Coated Mg for Biomedical Applications 437 N. Elmrabet, M. Roe, N. Neate, D. Grant, and P. Brown

Functional and Emerging Alloys Microstructure and Mechanical Properties of a Magnesium-Aluminium-Erbium Alloy 445

S. Sankaranarayanan, B. Ng, S. Jayalakshmi, M. Kumar, Q. Nguyen, and M. Gupta

Microstructure and Properties of Cobalt-and Zinc-Containing Magnetic Magnesium Alloys Processed by High-Pressure Die Casting 451

C. Klose, C. Demminger, and H. Maier

Effects of La Addition on Thermal Conductivity and Mechanical Properties of Mg-4Zn-0.5CaO Alloys 455 G. Oh, Y. Yoon, S. Kim, H. Lim, and Y. Kim

Strip Casting of Light Metals

Modeling and Properties Twin Roll Casting of Magnesium Strip at Canmet Materials - Modeling and Experiments 461

A. Javaid, J. Hanke, C. Simha, and M. Kozdras

Microstructure Evolution of Different Magnesium Alloys during Twin Roll Casting 465 G. Kurz, J. Wendt, J. Bohlen, and D. Letzig

The Microstructure and Texture Development during Twin Roll Casting and Rolling of Magnesium Alloy AZ31 471

J. Bohlen, S. Yi, J. Victoria-Hernández, N. Schell, B. Schwebke, H. Brokmeier, G. Kurz, and D. Letzig

Process Technology Magnesium Twin-Roll Casting Benefits from Aluminium Heritage 479

D. Basson

Innovations in the Process Technology for Manufacturing Magnesium Alloy Sheet 485 E. Romano, R. Passoni, and C. Romanowski

Author Index 491

Subject Index 495

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PREFACE

This is the 16th annual volume of papers from the Magnesium Technology symposium, which contains all aspects of magnesium technology, ranging from primary production to applications and recycling, as well as basic research to industrialization. Continuing with the longstanding tradition of presenting the most recent and highest quality work on magnesium, all presenters have submitted papers to this edited proceedings volume or other TMS-sponsored peer-reviewed journals. All papers in this compendium were thoroughly reviewed by experts, leading researchers, and industrialists in the field, and their contribution continues to be an important aspect to the success of this symposium. This proceedings volume is highly regarded as a centralized repository of magnesium research carried out globally and includes the finest and latest breaking articles in this area. Papers in this collection originated from 19 countries, highlighting the global competitiveness and interest in magnesium technology. This collection of papers represents the spectrum of research that will be presented during the 2015 Magnesium Technology Symposium at the 144th T M S Annual Meeting & Exhibition held in Orlando, Florida from March 15-19, 2015. This is one of the largest yearly gatherings of magnesium specialists in the world.

The symposium will start with a keynote session that consists of several distinguished invited speakers who were carefully selected as world-class experts who could provide their perspective on the future possibilities and opportunities on the topic of magnesium alloy research and development. The keynote speaker, Alan Taub, professor at the University of Michigan and the Chief Technical Officer of the American Lightweight Materials Manufacturing Innovation Institute (ALMMII), will provide us an overview of the activities of the institute, which constitutes one arm of the federal National Network for Manufacturing Innovation (NNMI) initiative, proposed by President Obama, and serves as a hub to accelerate the development and adoption of cutting-edge advanced lightweight materials and manufacturing technologies. His talk will be followed by a presentation by Bruce Davis from Magnesium Elektron, who will discuss the ongoing and recently standardized efforts by the Federal Aviation Authority to integrate magnesium alloys into structural applications in commercial aircraft. Tresa Pollock, professor at the University of California Santa Barbara, will summarize the outcomes of a recently held National Science Foundation-sponsored workshop to identify emerging and transformative research areas in metals and metallic nanostructures, where magnesium technology was highlighted as a topical area of interest. These broad-ranging, overview keynote session talks will be followed by a set of distinguished scientists, Jian-Feng Nie (Monash University), Matthew Barnett (Deakin University), and Sean Agnew (University of Virginia) who will discuss their latest technical research.

This year, integrated into the plenary are two new activities: (1) poster authors will be presenting elevator-pitch style presentations of their posters which will be later displayed during the poster session following the completion of the keynote session, and (2) the keynote speakers will participate in a panel for an interactive discussion with the audience on the future of magnesium research and applications. This discussion will be dictated, summarized, and then transcribed into a manuscript that will be subsequently released to the community.

Due to the large number of manuscripts submitted, each of the four days of the symposium are organized in parallel sessions of technical presentations, with two parallel sessions dedicated to the specialty symposium on Strip Casting of Light Metals organized by Kai Karhausen (Hydro Aluminium Rolled Products GmbH), Wim Sillekens (European Space Agency), Murat Diindar (Assan Aluminium), Jan Bohlen (Helmholtz-Zentrum Geesthacht), and Dietmar Letzig (Helmholtz-Zentrum Geesthacht). This

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symposium is co-sponsored by the Aluminum and Magnesium Committees and is dedicated to continuous casting/rolling methods to directly transform aluminum or magnesium melts into (semi-finished) strip, thereby emphasizing scientific technological communalities in the processing of both light-metal classes. Implemented as twin-roll casting, the manufacturing of magnesium-alloy strip is currently one of the highlights in magnesium research and development with particular relevance to automotive applications.

We would like to gratefully acknowledge and thank all the authors for their contributions and, in addition, the reviewers, session chairs, and poster judges for their willingness to volunteer their time in order to ensure a successful, high quality symposium and proceedings volume.

2015 Magnesium Technology Conference Organizers

Michele V. Manuel, Chair Alok Singh, Vice Chair Martyn Alderman, Past Chair Neale R. Neelameggham, Advisor

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ABOUT THE LEAD EDITOR

MICHELE V. MANUEL MAGNESIUM TECHNOLOGY 2015 LEAD EDITOR

Michele Manuel is an associate professor in the Department of Materials Science and Engineering at the University of Florida. She received her Ph.D. in materials science and engineering at Northwestern University in 2007 and B. S. in materials science and engineering at the University of Florida. Prior to arriving at the University of Florida, she performed her post-doctoral work at the General Motors Technical Center in Warren, Michigan. She is the recipient of the NSF CAREER award, NASA Early Career Faculty award, ASM Bradley Stoughton Award for Young Teachers, AVS Recognition for Excellence in Leadership, TMS Early Career Faculty award, TMS Young Leaders Professional Development award, and TMS/JIM International Scholar award. Her research lies in the basic understanding of the relationship between processing, structure, properties, and performance. She uses a systems-based materials design approach that couples experimental research with theory and mechanistic modeling for the accelerated development of materials. Her current research is focused on the use of systems-level design methods to advance the development of new materials through microstructure optimization. In the TMS Magnesium Committee, she has previously served in the roles of Vice Chair, Secretary, and JOM Advisor, and she currently serves as Chair. Additionally, she serves as the Vice Chair of the Content Development and Dissemination Committee, as well as a member of the Education, Young Leaders, Integrated Computational Materials Engineering Committee (ICME), and the Women in Science Committees.

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MAGNESIUM TECHNOLOGY 2015 EDITORS Alok Singh Alok Singh is a Chief Researcher in the Structural Materials Unit of National Institute for Materials Science in Tsukuba, Japan. He studied metallurgical engineering at undergraduate, masters and doctoral levels. His master's thesis at Indian Institute of Technology at Kanpur, 1987, was on kinetics of phase transformation in steels. His Ph.D. work, at the Indian Institute of Science, was on the study of quasicrystalline and related intermetallic phases in aluminum alloys by transmission electron microscopy (TEM). He tackled the complex structures and reciprocal space of quasicrystals and its indexing problems. Subsequently, he worked several years studying advanced materials by TEM at the Indira Gandhi Center for Atomic Research, and visited National Research Institute for Metals in Japan. He studied the effect of interfaces on melting and solidification of embedded nanoparticles, and the structure of interfaces between simple crystals and quasicrystals. In 2002 he moved to his present working place and started work on magnesium alloys with special emphasis on Mg-Zn-RE alloys containing stable quasicrystal phase. His work has demonstrated very high strength with ductility in these alloys. He has employed TEM to study dislocations, grain boundaries and twins to understand deformation behavior of magnesium alloys. He has over 80 refereed publications, over 30 contributions to proceedings, and several patents on magnesium alloys. He is a regular attendee of TMS Annual Meetings & Exhibition and has been involved with the Magnesium Committee for many years. He received the TMS Magnesium Fundamental Research Award for year 2009 along with his coworkers.

Martyn Alderman Martyn Alderman is Divisional Director of Technology for the Magnesium Elektron Group Worldwide. He obtained a master's degree in material science from the University of Cambridge (United Kingdom) in 1979 and for the next 20 years he worked in aluminum rolling mills producing and developing Al-Cu-Zr, Al-Mn, A1 Mg-Mn, Al-Zn-Mg, and Al-Li-Cu alloys for superplastic forming. He also has significant operational experience direct chill casting and in the extrusion of high strength aluminum alloys.

In 2003 he joined Magnesium Elektron during the acquisition of their large Madison, Illinois rolling operation in the United States. For the next few years he was travelling between the United States and Europe encouraging the wider use of magnesium sheet in transport applications, in particular by use of superplastic forming, and later in managing the post-acquisition integration of the Revere North American Graphic Arts business. He chaired the 2010 International Magnesium Association Conference in Hong Kong, and in 2011-12 was involved in editing and producing a 270-page Handbook on Designing with Magnesium Alloys.

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More recently he has been involved in a UK Technology Strategy Board Project aimed at the design of a magnesium intensive vehicle in conjunction with the Morgan Motor Company, and as an advisor to the International Magnesium Association Life Cycle Study on automotive and aerospace applications. As a member of TMS, SAE, and AMS, he is a regular attendee at worldwide magnesium conferences keeping abreast of global technology development with the aim of maintaining the Magnesium Elektron's position as a world leader in magnesium alloys and their end use applications.

During 2015 he will again be chairing the International Magnesium Conference in Vancouver, and participating in the organization of the 10th International Conference on Magnesium Alloys and their Applications on Jeju Island in South Korea.

Neale R. Neelameggham Neale R. Neelameggham is 'The Guru' at IND LLC, involved in technology marketing and international consulting in the field of light metals and associated chemicals (boron, magnesium, titanium, lithium and alkali metals), rare earth elements, and battery and energy technologies, etc. He was recently a visiting expert at Beihang University of Aeronautics and Astronautics, Beijing, China. He has over 38 years of expertise in magnesium production and was involved in process development of its startup company NL Magnesium through to the present US Magnesium LLC, UT from where he retired in 2011. He is developing thiometallurgical processes - a new concept of using sulfur as the reductant and or fuel. He has published a heat transfer model for global anthropogenic warming based on thermal emissions independent of energy conversion source.

Dr. Neelameggham holds 16 patents and patent applications, and has published several technical papers. He has served in the Magnesium Committee of the TMS Light Metals Division (LMD) since its inception in 2000, chaired it in 2005, and in 2007 he was made a permanent co-organizer for the Magnesium Technology Symposium. He has been a member of the Reactive Metals Committee, Recycling Committee, and Titanium Committee, and a Programming Committee Representative of LMD.

In 2008, Dr. Neelameggham was the inaugural chair of the Energy Committee, a joint committee between the TMS Light Metals and Extraction and Processing Divisions, and has been a co-editor of the Energy Technology symposium through the present. He received the LMD Distinguished Service Award in 2010. Neale is the Chairman of Hydrometallurgy and Electrometallurgy Committee of the Extraction and Processing Division for the 2013-2015 term, during which time he organized the Rare Metal Technology 2014 and 2015 symposia. He is the co-editor of the Essential Readings in Magnesium Technology compendium of TMS papers published in 2014. He is a co-editor of the 2015 symposium on Drying, Roasting and Calcining.

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MAGNESIUM TECHNOLOGY 2015 Session Chairs

Keynote Session

Michele V. Manuel, University of Florida

Alok Singh, National Institute for Materials Science (NIMS)

Elevated Temperature and Creep Amit Pandey,

LG Fuel Cell Systems

Karl Kainer, Helmholtz-Zentram Geesthacht

Primary, Sustainability, Recycling, and Processing

Neale R. Neelameggham, IND LLC

James Saal, QuestTek Innovations, LLC

Deformation I Bilal Mansoor,

Texas A&M University at Qatar

Haitham El Kadiri, Mississippi State University

Deformation II Suveen Mathaudhu,

University of California, Riverside

Kiran Solanki, Arizona State University

Wrought Bin Li,

University of Nevada, Reno

Eric Nyberg, Pacific Northwest National Laboratory

Forming and Alloy Design James Saal,

QuestTek Innovations, LLC

Mesut Varlioglu, John Deere Moline Technology Innovation Center

Corrosion, Coatings, Fatigue, and Fracture Brian Jordon,

University of Alabama

Syamala Pulugurtha, Medtronic

Casting and Metal Matrix Composites Lei Zhang,

University of Alaska, Fairbanks

Wim Sillekens, European Space Agency

Biomedical Applications Raymond Decker,

Nanomag

Norbert Hort, Helmholtz-Zentram Geesthacht

Functional and Emerging Alloys Vineet Joshi,

Pacific Northwest National Laboratory

STRIP CASTING OF LIGHT METALS Session Chairs

Modeling and Properties Dietmar Letzig,

Helmholtz-Zentram Geesthacht

Murat Diindar, Assan Aluminium

Process Technology Kai F. Karhausen,

Hydro Aluminium Rolled Products

Jan Bohlen, Helmholtz-Zentram Geesthacht

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MAGNESIUM TECHNOLOGY 2015 Reviewer Pool

The completion of this volume would not have been possible without the volunteer assistance of these individuals from 19 different countries. Their commitment to the advancement of magnesium research and scientific knowledge is to be commended. They are listed here in alphabetical order by their last names:

AGNEW, Sean University of Virginia BERMAN, Tracy University of Michigan CACERES, Carlos University of Queensland D'ERRICO, Fabrizio Politecnico di Milano DAVIS, Bruce Magnesium Elektron DIERINGA, Hajo MagIC-Magnesium Innovation Center DOHERTY, Kevin US Army Research Laboratory EL KADIRI, Haitham Mississippi State University FORSMARK, Joy Ford Motor Company GHADERI, Alireza Deakin University GUPTA, Manoj National University of Singapore HENDERSON, Hunter University of Florida HORT, Norbert Helmholtz Zentrum Geesthacht HUANG, Yuanding Helmholtz Zentrum Geesthacht JORDON, Brian University of Alabama JOSHI, Vineet Pacific Northwest National Laboratory JUNG, In-Ho McGill University KADA, Sitarama Raju Deakin University KAINER, Karl Helmholtz Zentrum Geesthacht KARAKAYA, Ishak Middle East Technical University KRAJEWSKI, Paul General Motors LI, Bin Mississippi State University MAIER, Petra University of Applied Sciences Stralsund MANUEL, Michele University of Florida MATHAUDHU, Suveen University of California Riverside MENDIS, Chamini Helmholtz Zentrum Geesthacht NAGASEKHAR, Anumalasetty Carpenter Technology Corporation NEELAMEGGHAM, Neale R. IND LLC NIE, Jian-Feng Monash University NYBERG, Eric Pacific Northwest National Laboratory PANDEY, Amit Rolls Royce LG Fuel Cell Systems Inc.

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POWELL, Adam PRENTICE, Leon PULUGURTHA, Syamala Rani RAVINDRA, N.M ROHATGI, Aashish ROSALIE, Julian SAAL, James SEVER, James SILLEKENS, Wim SOLANKI, Kiran ST JOHN, David TALEFF, Eric TARTAGLIA, John TOLNAI, Domonkos VERMA, Ravi WILKS, Tim

Infinium Metals CSIRO Medtronic New Jersey Institute of Technology Pacific Northwest National Laboratory National Institute for Materials Science QuesTek Innovations, LLC Alpha/Omega Engineering European Space Agency Arizona State University University of Queensland University of Texas Element Materials Technology MagIC Magnesium Innovation Center General Motors Magnesium Elektron

X X

Magnesium Technology

2015

Keynote Session

Magnesium Technology 2015 Edited by: Michele V. Manuel, Alok Singh, Martyn Alderman, andNeale R. Neelameggham

TMS (The Minerals, Metals & Materials Society), 2015

REDUCING WEIGHT FOR TRANSPORTATION APPLICATIONS: TECHNOLOGY CHALLENGES AND OPPORTUNITIES

Alan I. Taub University of Michigan, Ann Arbor, 2300 Hayward Street, Ann Arbor, MI, 48109, USA

Keywords: lightweight materials, manufacturing processes, systems engineering principles

Today's land, sea and air transportation industries - as a business necessity - are focused on technology solutions that will make vehicles more sustainable in terms of energy, the environment, safety and affordability. Reducing vehicle weight is a key enabler for meeting these challenges as well as increasing payload and improving performance. The potential weight reductions from substituting lightweight metals (advanced high-strength steels, aluminum, magnesium and titanium alloys) are well established. For magnesium castings, weight savings of 60% have been reported [1], The value of weight reduction depends on the transportation sector and ranges from about $5/kg saved for automobiles to over $500/kg saved for aircraft [2]. The challenge is to optimize the material properties and develop robust, high volume, manufacturing technologies and the associated supply chain to fabricate components and subsystems at the appropriate cost for each application.

The American Lightweight Materials Manufacturing Innovation Institute (ALMMII) was established as a public-private partnership to accelerate the adoption of these materials. ALMMII is one of four new institutes that are part of the growing National Network of Manufacturing Institutes and serves as the nation's essential bridge between basic research and final product commercialization for lightweight metals [3].

The institute will take advantage of opportunities to drive synergies across the various industries serving both commercial and defense transportation needs. Advanced manufacturing processes will be developed through projects executed by our industry partners in collaboration with an extensive network of universities and the national and federal laboratories. Commercialization of the resulting technologies is enabled by the early integration of the capabilities of the full production supply chain from material producers and metal formers to OEM's.

Improved manufacturing processes for magnesium in both cast and wrought forms are required to expand the alloy utilization. Our industry and government partners have identified a number of focus areas including higher integrity and larger thin-walled castings, overcasting of magnesium on aluminum and steel substrates, and joining of mixed-material components with particular emphasis on mitigation of galvanic corrosion.

The projects will employ systems engineering principles as shown in Figure 1. The industry members will select the particular alloy and an associated component and platform. In developing the new manufacturing process, the project team will employ ICME enabled models that can support both the design and certification/validation phases of the work.

S y s t e m Engineer ing D e s i g n

Lightweighting Commercializable Solutions • ICME e n a b l e d - m o d e l s

Inst i tute enab le rs :

• Faci l i t ies

- Exper t i se

- Supply chain ner.vork

Materials and Manufacturing Technology Foci

Figure 1 : Each ALMMII project will utilize systems engineering principles to deliver innovative manufacturing processes integrated with product design modeling

References [1] Alan I. Taub, Paul E. Krajewski, Alan A. Luo, and John N. Owens, The Evolution of Technology for Materials Processing over the Last 50 Years: The Automotive Example, JOM v 59, n 2, p 48-57, February 2007.

[2] Materials Research to Meet 21st Century Defense Needs, NRC

Committee on Materials Research for Defense After Next, National Academy Press, 2003. [3] National Network for Manufacturing Innovation: A Preliminary Design, Executive Office of the President, National Science and Technology Council, Advanced Manufacturing National Program Office, January, 2013

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Magnesium Technology 2015 Edited by: Michele V. Manuel, Alok Singh, Martyn Alderman, andNeale R. Neelameggham

TMS (The Minerals, Metals & Materials Society), 2015

THE APPLICATION OF MAGNESIUM ALLOYS IN AIRCRAFT INTERIORS CHANGING THE RULES

Bruce Davis Magnesium Elektron North America; 1001 College St. PO Box 258; Madison, IL, 62060, USA

Extended Abstract

The commercial aircraft market is forecast to steadily grow over the next two decades. Part of this growth is driven by the desire of airlines to replace older models in their fleet with newer, more fuel efficient designs, to realize lower operating costs and to address the rising cost of aviation fuel. As such the aircraft OEMs are beginning to set more and more demanding mass targets on their new platforms.

The cabin interior, including furnishings and operational items, account for 19% of the overall aircraft weight. This establishes it as a significant area for weight savings. Modern magnesium alloys can offer up to 30% mass reduction when directly replacing aluminum components, which makes them very attractive to designers and engineers. However, until recently, there have been restrictions on the use of magnesium in aircraft interiors that have been enforced through the SAE and the FAA.

The FAA has been working for the last seven years to assess the safety issues associated with the introduction of magnesium into the cabin interior. This work began with simplistic flammability testing of a wide range of alloys that identified different ignition behaviors of magnesium alloy types. This lead the FAA to undertake full scale fuselage staged burn tests of seat structures. The typical structural seat components are shown in Figure 1. The seats tested in the full-scale fuselage assessment contained five key parts fabricated from magnesium: spreader bars, seat leg assembly, cross tubes, baggage bars and the seat back frame.

(̂ Baggagê Bar)

Figure 1. Schematic of major structural seat components

The testing arrangement is shown in Figure 2, which indicates the monitoring systems that were in place. The test assessed standard seat ignition properties compared to two magnesium containing seats containing either AZ3IB alloy or Elektron®43.

FTOOasAnlpK Qmdnooos C*> Anitas

Heat F j r. TUa> Camera

^ Smoke MMer

Figure 2. Overview of full-scale fuselage test.

The results of this testing showed that the presence of magnesium did not compromise passenger safety. The FAA has now issued guidelines on a laboratory scale flammability test. The test setup is shown in Figure 3. Magnesium alloys that meet the criteria of this test will be considered allowable for use in aircraft seat applications. The test method is available in the FAA's Aircraft Materials Fire Test Handbook Chapter 25 Oil Burner Flammability Test for Magnesium Alloy Seat Structure

Figure 3. Lab scale burner test setup

The work by the FAA has culminated with a lifting of the ban of magnesium's application in aircraft seat applications. The FAA will now accept application for special conditions that will allow magnesium containing aircraft seat certification in commercial transport aircraft. Future work by the FAA will investigate methods of compliance (MOC) to allow magnesium in other aircraft interior applications, thereby extending the weight saving potential and benefit of today's advanced magnesium alloys.

Furthermore, the SAE standard AS8049 Rev B, which defines the engineering requirements of a commercial aircraft seat, restricts the use of magnesium in paragraph 3.3.3. AS8049 is currently undergoing its scheduled five year review. Revision C is scheduled to be issued in 2015 and paragraph 3.3.3 has been altered to allow the use of magnesium. The document now states that magnesium alloys maybe used in aircraft seats so long as the conform to the requirements set out in the Aircraft Materials Fire Test Handbook.

The application of the next generation magnesium alloys in aircraft interiors is now positioned to grow.

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Magnesium Technology 2015 Edited by: Michele V. Manuel, Alok Singh, Martyn Alderman, andNeale R. Neelameggham

TMS (The Minerals, Metals & Materials Society), 2015

EMERGING SCIENCE AND RESEARCH OPPORTUNITIES FOR METALS AND METALLIC NANOSTRUCTURES: A REPORT ON THE NSF MMN WORKSHOP

Tresa Pollock1, Carol Handwerker2

'University of California Santa Barbara; Materials Department; Santa Barbara, CA; 93106-5050; USA 2Purdue University; 701 W. Stadium Avenue; West Lafayette, IN; 47907; USA

Extended Abstract

In the next decade, fundamental research in metals and metallic nanostructures (MMN) has the potential to continue to transform science into innovative materials, devices, and systems. This talk summarizes the findings of a workshop to identify emerging and potentially transformative research areas in MMN. The metals and metallic nano structures (MMNs) workshop aimed to identify significant research trends, scientific fundamentals, and recent breakthroughs that can enable new or enhanced MMN performance, either alone or in a more complex materials system, for a wide range of applications. Additionally, the role that MMN research can play in high-priority research and development (R&D) areas such as the U.S. Materials Genome Initiative, the National Nanotechnology Initiative, the Advanced Manufacturing Initiative, and other similar initiatives that exist internationally was assessed. The workshop also addressed critical issues related to materials research instrumentation and the cyberinfrastructure for materials science research and education, as well as science, technology, engineering, and mathematics (STEM) workforce development, with emphasis on the United States but with an appreciation that similar challenges and opportunities for the materials community exist internationally.

The societal and economic impacts of MMN research will continue to be significant. Metals and metallic nanostructures underlie systems and technologies critical to solving national and global grand challenges. Innovations in metals, metal alloys, and metallic nanostructures are needed to advance systems for:

• energy generation, harvesting and storage -thermoelectrics, batteries, fuel cells, advanced turbines, magnetic induction, motors, hydrogen production and storage, nuclear reactor materials, separation membranes

• propulsion and transportation - high strength, high performance lightweight structures, materials designed for improved creep, impact, fatigue or corrosion resistance, high temperature metals, alloys and coatings for extreme environments, non-destructive evaluation

• electronics, telecommunication, and information technology - electronic packaging, process modeling, device nanostructures to overcome the end to Moore's law, thin film and nano structured electrical interconnects, magnetic devices and motors, and sensors

• sustainability - nano structured metals for catalytic converters, polymer catalysis, hydrogen and ammonia production, low pollution smelting and refining processes

• health care - imaging systems, integrated in-vivo sensors, electronics, and communication systems for health monitoring and drug delivery, prosthetics and implant materials and systems, cancer treatment technologies

• manufacturing - additive and nano-manufacturing technologies, non-equilibrium processing approaches, recycling and reuse, rapid deployment of alternatives to "critical" materials.

A central theme of the Workshop was the view that research in metals and metallic nanostructures has provided and will continue to provide benefit to the nation through the coupling of experiment, theory, and simulation to link atomistic, nanoscale, microscale, and mesoscale phenomena across time scales for an ever widening range of applications. Within this overarching theme, the workshop participants identified emerging research opportunities that are categorized in terms of:

• 3-D and 4-D Materials Science

• Structure Evolution and the Challenge of Heterogeneous and Multicomponent Systems

• The Science Base for Property Prediction Across the Lengthscales

• Nanoscale Phenomena at Surfaces - Experiment, Theory, Simulation

• Prediction and Control of the Morphology, Microstructure, and Properties of "Bulk" Nano structured Metals

• Functionality and Control of Materials Far from Equilibrium

• Hybrid and Multifunctional Materials Assemblies

• Materials Discovery and Design: Enhancing the Theory -Simulation - Experiment Loop

This talk will summarize the findings of the workshop and will provide a brief overview of these emerging research opportunities, along with challenges and opportunities for the materials community in the areas of instrumentation, cyberinfrastructure, education, and workforce development.

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