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Magnesium Alloy Strip Casting :: Total Materia Article
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Key to Metals AG
Magnesium Alloy Strip Casting
Magnesium alloys are well known for light weighting specifically in transportation and mobile electronics but have production restrictions relating to formability and therefore are primarily die casted.
Magnesium alloy strip casting combines casting and hot rolling into a single step process meaning good results can be gained whilst saving on equipment, running and energy costs.
Magnesium alloys are light-weight structural metals with high specific strengths, which have been used in transportation and mobile electronics for weight-saving. However, due to their poor formability, die casting has been te most popular process for making te parts until now. But in te future, te die casting process may not meet a new demand for lighter, thinner, stronger, and more complex shape applications.
On te other hand, te demand to reduce energy consumption increased te use of light-weight alloys in te automobile industry. As te lightest structural metal with a high specific strength and Young-module, magnesium and its alloys have been widely applied in this industrial area.
Most magnesium alloy components have been produced by various die casting processes for its good casting behavior. Despite te fact that wrought flat products are more convenient to use, less than one percent of magnesium alloys are provided as sheets because wrought magnesium sheets are now still quite expensive and difficult to produce.
Therefore, te development of new forming processes for magnesium sheets is expected in order to lower te production cost and extend te application fields.
Te strip casting process combines casting and hot rolling into a single step, with advantages of low equipment cost, low running cost, energy saving and space saving. Te flow chart of continuous casting strip technology is shown in Figure 1.
Figure 1: Te continuous casting strip technology plant flow chart
In te process, te tundish feeds a transition piece, which is situated just above te delivery nozzle, and te molten metal is solidified starting at te point of first metal-roll connection and ending at te end point of solidification. This near-net-shape process can produce thin strip in one step. Upon exit from te casting roll, te solidified strip is directed to a pinch roll then through a hot rolling stand. In te transition, te atmosphere is controlled to limit oxidation of te strip and te formation of scale.
Referring to te automotive sector, magnesium sheets offer new opportunities for lightweight constructions, primarily in te car body, but also in chassis, interior, and motor components. Table 1 shows a list of possible components for an automotive application which can reasonably be made using magnesium sheets. Figure 2 represents some prototypes made out of magnesium alloy AZ31.
Table 1: List of possible Mg components for automotive application
Figure 2: Inner door, car roof and radio housing
1. D-I Jang, Y-O Yoon, S-B Jung, S. K. Kim: Effect of CaO on AZ31 Mg Strip Castings, Materials Transactions, Vol. 49, No 5, 2008, p. 976 - 979;
2. J. Zeng, R. Koitzsch, H.t Pfeifer, B. Friedrich: Numerical simulation of te twin-roll casting process of magnesium alloy strip, journal of materials processing technology 2 0 9, 2 0 0 9, p.2321–2328;
3. G-S.Wang, H-S. Di, F.Huang: Preparation of AZ31 magnesium alloy strips using vertical twin-roll caster, Trans. Nonferrous Met. Soc. China 20, 2010, p.973−979;
4. Y.Zhang: Modelling of vertical twin roll casting of magnesium alloy, Master of Engineering thesis, Faculty of Engineering, University of Wollongong, 2012, Australia;
5. M. Ullman, F. Berge, K.Neh, R.Kawalla, H-P Vogt: Application of Magnesium sheets and strips in vehicle construction, Accessed Oct 2016;
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