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Content archived on 2024-05-30

Development and Implementation of Magnesium sheets in A/C

Final Report Summary - DIMAG (Development and Implementation of Magnesium sheets in A/C)

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 seems that the project results proved the applicability of the advanced magnesium alloy in future aero-structures.

Project Context and Objectives:
The project dealt with the feasibility of several procedures related to magnesium sheet forming {stamping, press draw, press bending, lubricant pre-cleaning} and some non-chromate coating applications as well. In order to run the forming trials, some new tool systems had to be designed and manufactured. Due to the structural nature of magnesium based alloys, the forming processes require hot working, so the tooling systems designed to be operated at high temperatures (up to 500C).
Set of working parameters such as: process order and number of steps / blank geometry / surface polishing / pre heating / forming temperatures / stress relieving / lubrication, have been adjusted for each of the procedures.
The main goal was to provide an effective manufacturing process for each step and to be able to compare performance with reference material, such as conventional Mg alloy AZ31B.
By the time of the end of the project, partners are able to obtain the new process sequences as well as the manufacture parameter for each step and to understand the main differences between handling of old/conventional magnesium alloys and new alloy type which provides higher strength and better isotropy in sheet form.

Project Results:
These are the main S & T results:
a. Elektron 43 magnesium sheet can basically be shaped, by the same forming procedures which have been selected and examined during the present project, to the same forming limits that can be achieved with the conventional magnesium alloy – AZ31B.
b. The Elektron 43 mechanical properties could be kept during the sheet forming steps. No further second phase segregation has been observed.
c. T5 aging treatment should be performed upon the formed part.
d. The temperature degree during Elektron 43 forming is much higher than the level required during AZ31 (up to 60% higher).
e. Tooling design should take into consideration the high temperature process and the Elektron 43 excellent heat resistance.
f. ARDROX 1770 anodizing protection process has excellent reaction with Elektron 43 alloy and can be easily applicable.
g. Assembly by mechanical riveting should be studied in relation with specific surface treatment, no matter if AZ31B or Elektron 43 are selected for the structure substrate.

Potential Impact:
The potential impact of DIMAG project is facilitation in 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 will contribute to all the abovementioned goals.
Finally it is the responsibility of the aircraft manufacturing companies (in this case, IAI) to make efforts in order to introduce as many as magnesium parts to aircraft.
Introduction of more and more magnesium parts into aircraft worldwide will surely lead to increase of jobs and employment.
Dissemination: the manufactured final part - Shelf Removal Assy - is going to be exhibited in the Paris Air Show 2013.
Mr. Yonatan Henn, the project coordinator and CEO of Aero-Magnesium is the point of contact for more information about the project work and results.