Friedrich / Mordike Magnesium Technology

Metallurgy, Design Data, Applications
1. Auflage 2006
ISBN: 978-3-540-30812-6
Verlag: Springer Berlin Heidelberg
Format: PDF
Kopierschutz: 1 - PDF Watermark

E-Book, Englisch, 677 Seiten

Magnesium, with a density of 1.74 g/cm², is the lightest structural metal and magnesium are increasingly chosen for weight-critical applications such as in land-based transport systems. 'Magnesium Technology' substantially updates and complements existing reference sources on this key material. It assembles international contributions from seven countries covering a wide range of research programs into new alloys with the requisite property profiles, i.e., the current state of both research and technological applications of magnesium. In particular, the international team of authors covers key topics, such as: casting and wrought alloys; fabrication methods; corrosion and protection; engineering requirements and strategies, with examples from the automobile, aerospace, and consumer-goods industries, and recycling. This authoritative reference and overview addresses materials researchers as well as design engineers.

Autoren/Hrsg.

Friedrich, Horst E.

Mordike, Barry Leslie

Inhaltsverzeichnis

1;Preface/Foreword;5
1.1;Dr. Horst E. Friedrich;7
1.2;Prof. Dr Barry L. Mordike;7
2;List of Contributors;9
3;Contents;13
4;1 History;23
4.1;1.1 History until 1945;23
4.1.1;1.1.1 Asia;23
4.1.2;1.1.2 Australia;24
4.1.3;1.1.3 Europe;24
4.1.4;1.1.4 North America;30
4.2;1.2 History Since 1945;34
4.2.1;1.2.1 Production;34
4.2.2;1.2.2 Applications;42
4.3;References;50
5;2 Production Technologies of Magnesium;51
5.1;2.1 Introduction;51
5.2;2.2 Raw Materials for Magnesium Production;52
5.2.1;2.2.1 Magnesite;53
5.2.2;2.2.2 Dolomite;53
5.2.3;2.2.3 Bischofite;53
5.2.4;2.2.4 Carnallite;53
5.2.5;2.2.5 Serpentine;54
5.2.6;2.2.6 Sea Water;54
5.3;2.3 Electrochemical Methods;55
5.3.1;2.3.1 Preparation of Magnesium Chloride Salts from Natural Raw Materials;55
5.3.2;2.3.2 Drying Magnesium Chloride Salts;57
5.3.3;2.3.3 Electrolysis of Magnesium Salts;58
5.3.4;2.3.4 Types of Electrodes in the Electrolysis Cells;61
5.3.5;2.3.5 Structure of the Electrolysis Cells;63
5.3.6;2.3.6 Operation of Electrolysis Cell;64
5.3.7;2.3.7 Refining Raw Magnesium Produced by Electrochemical Methods;65
5.3.8;2.3.8 Industrial Methods for Electrochemical Production;66
5.4;2.4 Thermal Reduction Methods;74
5.4.1;2.4.1 Preparation of Raw Material and Thermal Reduction Method;74
5.4.2;2.4.2 Industrial Methods with Thermal Reduction;74
5.4.3;2.4.3 Collection and Refining the Raw Magnesium Produced by Thermal Reduction;80
5.5;2.5 Advantages and Disadvantages of Electrolytic Production Versus Thermal Reduction Methods;81
5.6;References;82
6;3 Physical Metallurgy;85
6.1;3.1 Introduction;85
6.2;3.2 Properties of Pure Magnesium;85
6.2.1;3.2.1 Atomic Properties;85
6.2.2;3.2.2 Electron States;86
6.2.3;3.2.3 Lattice Parameters;86
6.2.4;3.2.4 Thermal Expansion;87
6.2.5;3.2.5 Density;87
6.2.6;3.2.6 Thermodynamic Properties;87
6.2.7;3.2.7 Diffusion;87
6.2.8;3.2.8 Thermal Conduction;88
6.2.9;3.2.9 Elastic Moduli;90
6.2.10;3.2.10 Damping Capacity;90
6.2.11;3.2.11 Deformation Behavior;96
6.2.12;3.2.12 Strengthening Mechanisms;97
6.3;3.3 Magnesium Alloys;101
6.3.1;3.3.1 Common Alloying Elements;102
6.3.2;3.3.2 Elements Used for Manufacturing Purposes or Impurities;104
6.3.3;3.3.3 Classification of Alloys;104
6.4;3.4 Phase Diagrams;106
6.4.1;3.4.1 Conventional Alloys;106
6.4.2;3.4.2 Higher Systems;112
6.5;3.5 Commercial Alloy Systems;114
6.5.1;3.5.1 Magnesium Die Casting Alloys (Zirconium Free);115
6.5.2;3.5.2 Permanent Mould, Sand and Investment Casting Alloys;116
6.5.3;3.5.3 Further Development;118
6.5.4;3.5.4 Highly Creep Resistant Alloys;119
6.6;Acknowledgements;124
6.7;References;124
6.8;Appendix;127
7;4 Melting, Alloying and Refining;131
7.1;4.1 Zirconium-Free Alloys;131
7.1.1;4.1.1 Mg-Al, Mg-Al-Zn, and Mg-Al-Si Alloys;131
7.1.2;4.1.2 Mg-Al-(Rare-Earth) Alloys;143
7.1.3;4.1.3 Mg-Al-(Alkaline Earth) Alloys;144
7.1.4;4.1.4 Mg-Li Alloys;146
7.2;4.2 Alloys Containing Zirconium;150
7.2.1;4.2.1 Introduction;150
7.2.2;4.2.2 Mechanism of Grain Refinement by Zirconium;150
7.2.3;4.2.3 Effect of Other Alloying Elements;153
7.2.4;4.2.4 Methods of Introducing Zirconium;155
7.2.5;4.2.5 Melting, Alloying Procedures for Other Elements;161
7.3;References to Chapter 4.1;163
7.4;References to Chapter 4.2;165
8;5 Magnesium Casting Alloys;167
8.1;5.1 Casting Alloys;167
8.1.1;5.1.1 Introduction;167
8.1.2;5.1.2 Alloying Principles;168
8.1.3;5.1.3 Casting Methods;184
8.1.4;5.1.4 Alloys for Diecasting;188
8.1.5;5.1.5 Alloys for Sand Casting;220
8.2;5.2 Wrought Alloys;226
8.2.1;5.2.1 Magnesium – Aluminum;230
8.2.2;5.2.2 Magnesium – Manganese (M-alloys);232
8.2.3;5.2.3 Magnesium – Aluminum – Zinc (AZ-alloys);232
8.2.4;5.2.4 Magnesium – Zinc – Zirconium (ZK-Alloys);234
8.2.5;5.2.5 Magnesium – Zinc – Rare Earth (ZE-Alloys);234
8.2.6;5.2.6 Magnesium – Yttrium – Rare Earth (WE-Alloys);234
8.2.7;5.2.7 Magnesium – Thorium, Zirconium or Manganese (HK- and HM-Alloys);235
8.2.8;5.2.8 Magnesium – Lithium – Alloys (LA-Alloys);235
8.2.9;5.2.9 Other Wrought Alloys;236
8.3;References to Chapter 5.1;236
8.4;References to Chapter 5.2;239
8.4.1;Additional Readings;239
9;6 Technology of Magnesium and Magnesium Alloys;241
9.1;6.1 Casting;241
9.1.1;6.1.1 Sand Casting;241
9.1.2;6.1.2 Die Casting;256
9.1.3;6.1.3 Squeeze Casting, Thixocasting and Rheocasting;280
9.2;6.2 Forming;291
9.2.1;6.2.1 Rolling and Shut Forming;291
9.2.2;6.2.2 Extrusion, Forging;311
9.3;6.3 Magnesium Matrix Composites;337
9.3.1;6.3.1 Introduction;337
9.3.2;6.3.2 Reinforcements;341
9.3.3;6.3.3 Manufacturing;345
9.3.4;6.3.4 Interfaces;351
9.3.5;6.3.5 Alloys and Composites;353
9.3.6;6.3.6 Machining and Recycling;355
9.3.7;6.3.7 Corrosion;356
9.4;6.4 Joining;357
9.4.1;6.4.1 Motivation and Requirements;357
9.4.2;6.4.2 Joining Magnesium;358
9.4.3;6.4.3 Welding and Other Thermal Processes;371
9.4.4;6.4.4 Adhesive Bonding;387
9.4.5;6.4.5 Mechanical and Hybrid Joining;396
10;7 Corrosion and Surface Protections;453
10.1;7.1 Surface Treatments and Protection;453
10.1.1;7.1.1 Introduction;453
10.1.2;7.1.2 Passivation Properties of Magnesium-Based Materials in Air;454
10.1.3;7.1.3 Surface Treatment of Magnesium-Based Materials;455
10.2;7.2 Corrosion;491
10.2.1;7.2.1 Introduction;491
10.2.2;7.2.2 Magnesium Protective Films;491
10.2.3;7.2.3 Metallurgical Factors in the Corrosion of Alloys;492
10.2.4;7.2.4 Stress Corrosion;503
10.2.5;7.2.5 Corrosion Fatigue;504
10.2.6;7.2.6 Common Causes of Corrosion Failure;506
10.2.7;7.2.7 Enviromental Factors;510
10.2.8;7.2.8 Galvanic Corrosion/Selection of Fasteners;512
10.3;References to Chapter 7.1;516
10.4;References to Chapter 7.2;518
11;8 Engineering Requirements, Strategies and Examples;521
11.1;8.1 Automotive Applications in Europe;521
11.1.1;8.1.1 Introduction;521
11.1.2;8.1.2 Potential Use of Magnesium in Vehicles;525
11.1.3;8.1.3 Automotive Applications – Examples;528
11.1.4;8.1.4 Life Cycle Assessment;581
11.1.5;8.1.5 Strategy and Outlook;587
11.2;8.2 Automotive Applications in North America;591
11.2.1;8.2.1 Transportation Industry;591
11.2.2;8.2.2 Non-Automotive Uses for Magnesium;615
11.2.3;8.2.3 Magnesium Manufacturing in North America;616
11.2.4;8.2.4 Magnesium R&D in North America;622
11.3;8.3 Magnesium Aerospace;625
11.3.1;8.3.1 Background;625
11.3.2;8.3.2 Past Aerospace Use;629
11.3.3;8.3.3 Barriers to Magnesium Use in Aerospace;639
11.4;Conclusion;642
11.5;8.4 Consumer Applications of Magnesium;642
11.5.1;8.4.1 Logistics;643
11.5.2;8.4.2 Power Hand Tools;643
11.5.3;8.4.3 Lawn and Garden Equipment;645
11.5.4;8.4.4 Concrete Handling Tools and Equipment;645
11.5.5;8.4.5 Computers and Computer Hardware;646
11.5.6;8.4.6 Electronic Equipment;647
11.5.7;8.4.7 Optical Equipment;647
11.5.8;8.4.8 Sports Equipment;648
11.5.9;8.4.9 Galvanic Applications;649
11.5.10;8.4.10 Miscellaneous Consumer Applications;650
11.6;References to Chaper 8.1;651
11.7;References to Chaper 8.2;653
11.8;References to Chaper 8.3;653
12;9 Recycling;655
12.1;9.1 Introduction;655
12.2;9.2 Classification System;656
12.2.1;9.2.1 Process Overview;657
12.2.2;9.2.2 Class 1;658
12.2.3;9.2.3 Class 2;662
12.2.4;9.2.4 Class 3;662
12.2.5;9.2.5 Class 4;663
12.2.6;9.2.6 Class 5;663
12.2.7;9.2.7 Class 6;664
12.2.8;9.2.8 Class 7;665
12.2.9;9.2.9 Class 8;667
12.3;9.3 Recycling Using Flux;667
12.3.1;9.3.1 Principles;667
12.4;9.4 Fluxless Refining;669
12.4.1;9.4.1 Principles;670
12.4.2;9.4.2 Systems Involving Filters;671
12.5;9.5 Contamination Control;672
12.5.1;9.5.1 Additional Sources of Trace Elements and Inclusions During Recycling;673
12.5.2;9.5.2 Effects and Removal of Some Trace Elements;674
12.5.3;9.5.3 Effects of Inclusions;678
12.5.4;9.5.4 Measurements of Inclusions;678
12.6;9.6 Concluding Remarks;681
12.7;References;682
13;Subject Index;687