Development of new Magnesium Forming Technologies for …...2012/05/11 · super-plastic forming technologies for Magnesium wrought alloys. • Verification of the industrial feasibility

AEROMAG Workshop, Ottobrunn, 27.11.2008

Development of new Magnesium Forming Technologies for the Aeronautics Industry

Project no. AST5-CT-2006-030852

Dr. Gady I Rosen and Yonatan Henn – AMTS-PALBAM


OverviewDuration: 38 months (started August 2006).Budget: ~ €3.5M

The purpose of MagForming project is to advance the state of the art in the technology of plastic processing of wrought Magnesium alloys for aeronautical applications. This will be achieved by developing tools and manufacturing processes for industrial applications. The measure for attaining the objective is by attempting to fabricate several technology demonstrators, at least one for each of the considered forming technologies.


Overview of Partners

GermanyLeibnitz University Hanover

Czech Rep.Charles University Prague

IsraelAlubin

PolandUltratech

GermanyChemetall GmbH

RussiaSMW Engineering

FranceLiebherr Aerospace Toulouse

IsraelIsrael Aerospace Industry

GermanyAirbus Deutschland

UKMagnesium Elektron

GermanyEADS IW Deutschland

IsraelAMTS-PALBAM


The MagForming project of the EC 6th framework program

Motivation• Weight reduction of aircraft components.• Utilizing the outstanding lightweight potential of Magnesium alloys.• The lack of specific know-how and improvement of the relevant magnesium

alloy properties for forming.• The lack of industrial manufacturing technologies and process tools for the

aeronautical industry at a reasonable cost.

Objectives• Development of tools and methods for advanced, semi-industrial, plastic and

super-plastic forming technologies for Magnesium wrought alloys.• Verification of the industrial feasibility for aeronautics.

Forming technologies

• Deep drawing, forging, super-plastic sheet metal forming, creep forming, pad forming, roll bending.


Process Chain

Material characterization

FEA simulation

Design/Production of tools

Process development

Part analysis

Production of demonstrator

parts

Magnesium


Graphical presentation of work packages

WP3 Forging

WP4 SPF

WP5 Roll bending

and Pad forming

WP6 Deep drawing

WP7 Creep forming

WP

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WP10 assessment & reviewS

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WP9 Dissemination & Exploitation

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Partners Responsibility

Tools design and production, forging process.Leader of WP6

Institute of Metal Forming,Leibnitz University Hanover

12

Testing of feedstock and TDs.Leader of WP8

Department of Physics of Materials, Charles University Prague

11

Alloys selection, extrusion process development, pre-forgeslabs provider

Alubin10

Production of large scale forging toolsUltratech9

Lubricants developer and providerChemetall GmbH8

Tools design, forging process. Leader of WP3SMW Engineering7

Specifications, testing and TDs approving, R&A director.Leader of WP10

Liebherr Aerospace S.A.S.6

Specifications, testing and TDs approving. Leader of WP5Israel Aerospace Industry5

Specifications, testing and TDs approving.

Leader of WP2

Airbus Deutschland GmbH4

Alloy selection, rolling process development andmagnesium sheets production. Scientific director

Magnesium Elektron Ltd.3

D&E director, creep forming process, mechanical testing.Leader of WP7, WP9

EADS Deutschland GmbH2

Project coordination, tools design and production, forgingand deep drawing processes. Leader of WP1, WP4

Palbam Metal Works1

Main ContributionFull NameNo.


Materials Requirementsset up in FP6 project AEROMAG

Current Al-alloys: 5XXX (5083/5086/5053-0/5056 H11) and 2XXX (2024 T351)

Target Mg-alloy candidates: AZ31B, AZ80A, ZE10, ZK10A, ZK30A, WE43

(wrought material in form of sheets, plates, bars, extrusions)

Requirements of new Mg alloys for

Property Temperature systems application structural application

Tensile Ultimate Strength RT 275-350 MPa 450 MPa

Tensile Yield Strength RT 200-300 MPa 350 MPa

Elongation to fracture RT 12-16 % 16-18 %

Yield Strength 150°C - 10% of YTS -10% of YTS

Compressive Yield Strength RT ± 10% of YTS ± 10% of YTS

Failure under compression RT comparable Al 5083 comparable Al 2024 T3

Specific Weight RT 1,75 1,75

Residual Strength RT n.a. comparable to 2024 T3

Fatigue Crack Growth RT n.a. comparable to 2024 T3

Fatigue limit (Kt=1.0, R=0.1) RT 160 MPa 140 MPa


Testing Criteria

Tests & characterisation: Reference Standard:

Chemical composition & microstructure AIMS 03-04-000

Tension tests (L & LT direction) IGC 04-21-111 (ASTM B 557)

Compression (L & LT direction) ASTM E 209

Bearing (e/D=1,5 & e/D=2, L & LT) ASTM E 238-84

Fatigue

R=0,1; „type T“ Kt=2,3; T-L direction ASTM E 466-82

R= -1; Kt=1,036; T-L direction ASTM E 466-82

FCG (CCT W=400mm; R= 0,1; T-L) AITM 1-0042 (ASTM E 647-00)

R-Curve (CCT W=400mm; L-T & T-L) AITM 1-0043 (ASTM E 561-98)

Thermal stability: 1000h exposure @ 85°C (Tension Test; R-Curve)


Forging – large scale

Application: A340 Window frame

Partners: Airbus, SMW-E, Ultratech, MEL & Chemetall

Alloys:AZ31B spec grade plate and AZ80 cast slab

Material supplied: to SMW-E 21mm x 420mm x 520mm


Forging – medium scale

Application: Compressor Impeller for air conditioning system

Partner: Liebherr, IFUM, MEL & Chemetall

Alloys: WE43 extruded forging stock; AZ80 forging stock

Dimensions: Ø134mm x 173mm


Forging – small scale

Application: A380 Door stop fitting

Partner: Airbus, IFUM, MEL & Chemetall

Alloys: WE43 extruded forging stock; AZ80 forging stock

Dimensions: Ø68mm x 60mm

66 mm60 mm

50 mm


Super Plastic Forming

Application: G-200 Service door inner panel

Partner: IAI, Palbam-AMTS & MEL

Alloys: AZ31B-H24 & ZK10

2.0mm x 775mm x 1300mm

760mm / 29.921”

13

00m

m /

51

.1811

”


Rubber Pad Forming

Application: G-200 Leading edge ribs

Partner: IAI

Alloys: AZ31B-H24 1.5mm x 220mm x350mm

ZE10-F 1.5mm x 220mm x 350mm

Application: Demonstrator Part

Partner: Airbus

Alloys: AZ31B-H24 2mm x 600mm x 1250mm

ZE10 2mm x 600mm x 1250mm

IAI reference part


Roll Bending

Application: G-100 Side Panel

Partner: Israeli Aerospace Industry (IAI) & AMTS

Alloys: AZ31B-H24 1.5mm x 400mm x 1000mm

ZE10 1.5mm x 400mm x 1000mm

Rolled demonstrators


Deep Drawing

Application: Compressor Scroll

Partner: Liebherr, IFUM, Palbam-AMTS & Chemetall


ZE10 1.3mm x 600mm x 600mm


Deep Drawing

Application: Antenna Cover

Partner: IFUM, Palbam-AMTS, MEL & Chemetall


ZE10 1.3mm x 650mm x 800mm


Creep Forming (and laser welding)

Application: Demonstrator stiffened panel with a double curvature

(Part to be laser welded)

Partner: EADS, Alubin & MEL

Alloys: AZ31B-O 2mm x 150mm x 1000mm; 2mm x 1000mm x 1000mm

ZK10 2mm x 150mm x 1000m; 2mm x 1000mm x 1000mm


Thank you for your attention!

Documents

Development of new Magnesium Forming Technologies for …...2012/05/11 · super-plastic forming technologies for Magnesium wrought alloys. • Verification of the industrial feasibility