Skip to main content
SpringerLink
Log in

Magnesium Front End Research and Development: A Canada-China-USA Collaboration

  • Chapter
Essential Readings in Magnesium Technology

Abstract

The Magnesium Front End Research & Development (MFERD) project is an effort jointly sponsored by the United States Department of Energy, the United States Automotive Materials Partnership (USAMP), the Chinese Ministry of Science and Technology and Natural Resources Canada (NRCan) to demonstrate the technical and economic feasibility of a magnesium-intensive automotive front end body structure which offers improved fuel economy and performance benefits in a multi-material automotive structure. The project examines novel magnesium automotive body applications and processes, beyond conventional die castings, including wrought components (sheet or extrusions) and high-integrity body castings. This paper outlines the scope of work and organization for the collaborative (tri-country) task teams. The project has the goals of developing key enabling technologies and knowledge base for increased magnesium automotive body applications. The MFERD project began in early 2007 by initiating R&D in the following areas: crashworthiness, NVH, fatigue and durability, corrosion and surface finishing, extrusion and forming, sheet and forming, high-integrity body casting, as well as joining and assembly. Additionally, the MFERD project is also linked to the Integrated Computational Materials Engineering (ICME) project that will investigate the processing/structure/properties relations for various magnesium alloys and manufacturing processes utilizing advanced computer-aided engineering and modeling tools.

This is a preview of subscription content, log in via an institution to check access.

Access this chapter

Log in via an institution
Chapter
USD 29.95
Price excludes VAT (USA)
  • Available as PDF
  • Read on any device
  • Instant download
  • Own it forever
eBook
USD 189.00
Price excludes VAT (USA)
  • Available as PDF
  • Read on any device
  • Instant download
  • Own it forever
Hardcover Book
USD 169.99
Price excludes VAT (USA)
  • Durable hardcover edition
  • Dispatched in 3 to 5 business days
  • Free shipping worldwide - see info

Tax calculation will be finalised at checkout

Purchases are for personal use only

Institutional subscriptions

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

References

  1. J.A. Carpenter, J. Jackman, N. Li, R.J. Osborne, B.R. Powell and P. Sklad, “Automotive Magnesium Research and Development in North America”, Materials Science Forum, 2007, vols. 546–549, pp. 11–24.

    Google Scholar 

  2. W. Shi, X. Zhang and Q. Wang, “Magnesium Research and Development in China”, presentation at Magnesium Technology Symposium, TMS Annual Meeting, Orlando, FL, USA, February 25 — March 1, 2007.

    Google Scholar 

  3. K.U. Kainer, “Magnesium — Alloys and Technologies”, Wiley-VCH, Weinheim, Germany, 2003.

    Book  Google Scholar 

  4. A.A. Luo, “Magnesium: Current and Potential Automotive Applications”, JOM Journal of Metals, 2002, 54, (2), pp. 42–48.

    Article  Google Scholar 

  5. G.S. Cole, “Issues that Influence Magnesium’s Use in the Automotive Industry”, Magnesium Alloys 2003, Materials Science Forum, Trans Tech, Switzerland, 2003, vols. 419–422, pp. 43–50.

    Google Scholar 

  6. S. Schumann and H. Friedrich, “Current and Future Use of Magnesium in the Automobile Industry”, ibid, pp. 51–56.

    Google Scholar 

  7. A.A. Luo, “Recent Magnesium Alloy Development for Automotive Powertrain Applications”, ibid, pp. 57–66.

    Google Scholar 

  8. T. Kaneko and M. Suzuki, “Automotive Applications of Magnesium Alloys”, ibid, pp. 67–72.

    Google Scholar 

  9. J.S. Balzer, P.K. Dellock, M.H. Maj, G.S. Cole, D. Reed, T. Davis, T. Lawson and G. Simonds: “Structural Magnesium Front End Support”, SAE Technical Paper 2003-01-0185 (SAE International, Warrendale, PA, 2003).

    Book  Google Scholar 

  10. M. Hoeschl, W. Wagener and J. Wolf, “BMW’s Magnesium-Aluminium Composite Crankcase, State-of-the-Art Light Metal Casting and Manufacturing”, SAE Technical Paper 2006-01-0069, SAE International, Warrendale, PA, 2006.

    Google Scholar 

  11. C.J. Duke and S. Logan, “Lightweight Magnesium Spare Tire Carrier”, Proceedings of the 64th Annual World Magnesium Conference, International Magnesium Association, Wauconda, IL 60084, USA, 75–80.

    Google Scholar 

  12. BMW Group, “Aluminum Use in the New BMW 5&6 Series: Strategy and Experiences”, presentation at the Aluminum Association Automotive Seminar, Livonia, MI, USA, Nov. 16, 2004.

    Google Scholar 

  13. A.A. Luo and R.C. McCune, “Magnesium Front End — AMD 603 and AMD 604”, Automotive Lightweighting Materials, The United States Department of Energy FY 2006 Progress Report, January 2007.

    Google Scholar 

  14. M.H. Maj and T. N. Meyer, “Ultra-Large Castings of Aluminum and Magnesium”, Automotive Lightweighting Materials, The United States Department of Energy FY 2005 Progress Report, August 2006.

    Google Scholar 

  15. Z. Liu, presentation at the “Magnesium Front End Research & Development” crashworthiness team web-meeting, July 19, 2007.

    Google Scholar 

  16. N. Atalia, “Numerical Modeling of Acoustic Performance of Magnesium Alloy flat Panels in Automobiles”, Progress report 1, PWGCS, 2007.

    Google Scholar 

  17. S. Logan, A. Kizyma, C. Patterson and S. Rama, “Lightweight Magnesium Intensive Body Structure”, SAE Technical Paper 2006-01-0523, SAE International, Warrendale, PA, 2006.

    Book  Google Scholar 

  18. S. Begum, D.L. Chen S. Xu and A.A. Luo, “Low Cycle Fatigue Properties of An Extruded AZ31 Magnesium Alloy”, paper to be submitted for publication, Oct. 2007.

    Google Scholar 

  19. B. Yuan, S. Yuan, B.-L. Jiang and F. Yuan, “Corrosion Resistance of Magnesium Alloy with Complex Surface-Modifying Micro-Arc Oxidation Coating and Organic Coating Studied by Neutral Salt Spraying”, Materials Protection, 2006, 9.

    Google Scholar 

  20. J. Villafuerte and W. Zheng, “Corrosion Protection of Magnesium Alloys by Cold Spray” Advanced Materials and Processes, September 2007, 53–54.

    Google Scholar 

  21. A.A. Luo and A.K. Sachdev, “Wrought Magnesium Research for Automotive Applications”, Magnesium Technology 2006, eds. A.A. Luo, N.R. Neelameggham, and R.S. Beals, TMS, Warrendale, PA, 2006, 333–339.

    Google Scholar 

  22. A.A. Luo and A.K. Sachdev: “Development of a New Wrought Magnesium-Aluminum-Manganese Alloy AM30”, Metallurgical and Materials Transactions A, 2007, 38A, 1184–1192.

    Google Scholar 

  23. M. Yang, F. Pan, R. Cheng and A. Tang, “Effects of Solutionized Al-10Sr Master Alloys on Grain Refinement of AZ31 Magnesium Alloy”, Journal of Alloys and Compounds, 2007, in press.

    Google Scholar 

  24. A.A. Luo and A.K. Sachdev, “Development of a Moderate Temperature Bending Process for Magnesium Alloy Extrusions”, Materials Science Forum, 2005, 488–489, 447–482.

    Google Scholar 

  25. P. Martin, D. Baragar, K.P. Boyle, A.A. Luo, J.J. Jonas, S. Godet, K.W. Neale, “Elevated Temperature Property Measurements for Warm Forming Aluminum Alloy Tubes”, in Proceedings of the 2nd International Light Metals Technology Conference 2005, Ed. Helmut Kaufmann, June 8–10, 2005, St. Wolfgang, Austria. 51–56.

    Google Scholar 

  26. W.H. Hunt Jr. and D.R. Herling, “Cost Assessment of Emerging Magnesium Sheet Production Methods”, United States Department of Energy Report, PNNL-15368, September 2005.

    Google Scholar 

  27. R. Verma, unpublished work, GM R&D, June 2007.

    Google Scholar 

  28. P.E. Krajewski, “Elevated Temperature Forming of Sheet Magnesium Alloys”, in Magnesium Technology 2002, ed. H.I. Kaplan, TMS, Warrendale, PA, 2002, pp. 175–179.

    Google Scholar 

  29. R. Verma and J.T. Carter, “Quick Plastic Forming of a Decklid Inner Panel with Commercial AZ31 Magnesium Sheet”, SAE Technical Paper 2006-01-0525, SAE International, Warrendale, PA, 2006.

    Book  Google Scholar 

  30. USAMP AMD604 Casting Task Team, “Magnesium Front End Research & Development” project casting trial, Contech, Dowagiac, MI, October 23, 2007.

    Google Scholar 

  31. A.A. Luo, “Wrought Magnesium Alloys and Manufacturing Processes for Automotive Applications”, SAE Technical Paper 2005-01-0734, SAE International, Warrendale, PA, 2005.

    Book  Google Scholar 

  32. G. Song, L. Liu and P.C. Wang, “Overlap Welding of Magnesium AZ31B Sheets Using Laser-Arc Hybrid Process”, Materials Science and Engineering A, 2006, 429 (1–2), 312–319.

    Article  Google Scholar 

  33. L. Liu, Z. Zhang and G. Song, “Mechanism and Microstructure of Oxide Fluxes for Gas Tungsten Arc Welding of Magnesium Alloy”, Metallurgical and Materials Transactions A. 2007, 38 (3), 649–658.

    Article  Google Scholar 

  34. X. Cao and M. Jahazi, “Use of Laser and Friction Stir Welding for Aerospace Magnesium Alloys”, Proceedings of the 3rd International Conference on Light Metals Technology 2007, September 24–26, 2007, Saint-Sauveur, Quebec, Canada.

    Google Scholar 

  35. J. Allison, B. Liu, K. Boyle, Randy Beals and L. Hector, Integrated Computational Materials Engineering (ICME) for Magnesium: An International Pilot Project”, presentation in Magnesium Technology 2008, TMS Annual Meeting, March 9–13, 2008, New Orleans, Louisiana, USA, 2008.

    Google Scholar 

Download references

Author information

Authors and Affiliations

  1. General Motors Research & Development Center, Warren, MI, USA

    Alan A. Luo

  2. Pacific Northwest National Laboratory, Richland, WA, USA

    Eric A. Nyberg

  3. CANMET - Materials Technology Laboratory, Ottawa, Ontario, Canada

    Kumar Sadayappan

  4. China Magnesium Center, Beijing, China

    Wenfang Shi

Authors
  1. Alan A. Luo
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Eric A. Nyberg
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Kumar Sadayappan
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Wenfang Shi
    View author publications

    You can also search for this author in PubMed Google Scholar

Editor information

Editors and Affiliations

  1. Materials Science Division, U.S. Army Research Office (ARO), USA

    Suveen N. Mathaudhu B.S.E., Ph.D. (Program Manager for Synthesis and Processing of Materials, Adjunct Assistant Professor) (Program Manager for Synthesis and Processing of Materials, Adjunct Assistant Professor)

  2. Department of Materials Science and Engineering, North Carolina State University, USA

    Suveen N. Mathaudhu B.S.E., Ph.D. (Program Manager for Synthesis and Processing of Materials, Adjunct Assistant Professor) (Program Manager for Synthesis and Processing of Materials, Adjunct Assistant Professor)

  3. The Ohio State University (OSU), Columbus, Ohio, USA

    Alan A. Luo (Professor of Materials Science and Engineering and Professor of Integrated Systems Engineering, Vice Chair of TMS Light Metals Division and SAE Materials Division and the Chair of SAE Non-Ferrous Metals Committee) (Professor of Materials Science and Engineering and Professor of Integrated Systems Engineering, Vice Chair of TMS Light Metals Division and SAE Materials Division and the Chair of SAE Non-Ferrous Metals Committee)

  4. IND LLC, Canada

    Neale R. Neelameggham (Guru) (Guru)

  5. Pacific Northwest National Laboratory (PNNL), Washington, USA

    Eric A. Nyberg B.S., M.S. (Chief Engineer) (Chief Engineer)

  6. New Materials & Energy Unit at the research and technology center, European Space Agency (ESA-ESTEC), Netherlands

    Wim H. Sillekens Ph.D. (project manager) (project manager)

Rights and permissions

Reprints and permissions

Copyright information

© 2016 The Minerals, Metals & Materials Society

About this chapter

Cite this chapter

Luo, A.A., Nyberg, E.A., Sadayappan, K., Shi, W. (2016). Magnesium Front End Research and Development: A Canada-China-USA Collaboration. In: Mathaudhu, S.N., Luo, A.A., Neelameggham, N.R., Nyberg, E.A., Sillekens, W.H. (eds) Essential Readings in Magnesium Technology. Springer, Cham. https://doi.org/10.1007/978-3-319-48099-2_6

Download citation

Publish with us

Policies and ethics

Search

Navigation