Abstract
With respect to its density, magnesium (Mg) has a high potential for lightweight components. Nevertheless, the industrial application of Mg is limited due to, for example, its sensitivity to corrosion. To increase the applicability of Mg, a process chain for the production of a Mg component with a complete aluminum (Al) cladding is presented. Hydrostatic co-extrusion was used to produce bar-shaped rods with a diameter of 20 mm. The bonding between the materials was verified by ultrasonic testing. Specimens with a length of 79 mm were cut off from the rods and forged by using a two-staged process. After the first step (Heading), the Mg core was removed partially by drilling to ensure a complete enclosing of the remaining Mg during the second forging step (Net shape forging). The geometry of the drilling hole and the heading die design were dimensioned with the Finite Element-simulation software FORGE. Hence, a complete Al-enclosed Mg component was achieved by using the described process chain and forming processes. Microstructural investigations confirm the formation of an intermetallic interface as expected.
Highlights
The use of lightweight construction and materials is one way for the automotive industry to limitCO2 emissions
Material composites from Mg and Al showed a good formability in contrast to other material combinations, where core fracture was observed [6]
Such studies have shown that an interface between Al and Mg is formed by diffusion during co-extrusion
Summary
The use of lightweight construction and materials is one way for the automotive industry to limitCO2 emissions. Many investigations have focused on pressing billet geometry, variations of cladding and core material (cladding: Mg, core: Al, and vice versa) [7], or geometry of co-extruded products (e.g., sheets [6], profiles [8], tubes [9] or bar-shaped rods [10,11,12]). Such studies have shown that an interface between Al and Mg is formed by diffusion during co-extrusion. It comprises two intermetallic phases, Al3 Mg2 and Al12 Mg17 , and ensures the connection between the materials
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