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Mg Alloys in Industry
This document discusses the use of magnesium alloys in aerospace applications, past concerns, and current solutions. It provides historical examples of magnesium alloy use in aircraft from 1943-1957. Past concerns included corrosion, but new corrosion resistant alloys have been developed like Elektron 21 and WE43. These alloys are now used in a variety of aircraft components and applications. Testing has shown these alloys have improved corrosion resistance and elevated temperature properties over older alloys. They also have better flame resistance and are less likely to ignite than other alloys like AZ91. Overall, new magnesium alloys are enabling greater use of the material in both aerospace and automotive applications.
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Mg Alloys in Industry
- 1. Magnesium Alloys inAerospace Applications, Past Concerns, Current Solutions Magnesium Alloys in Aerospace Applications, Past Concerns, Current Solutions Triennial International Aircraft Fire & Cabin Safety Research Conference October 29 - November 1, 2007 Bruce Gwynne – VP Divisional Strategic Development Paul Lyon - Market & Materials Development Manager
- 2. Mg Components onAircraft - Historical 1943 - 1944 (prototypes) Northrop XP-56 Black Bullet Experimental Flying Wing Fighter The All Magnesium Aircraft • Magnesium Alloy Airframe & Skin • Heliarc welded structure
- 3. Mg Components onAircraft - Historical 1949 - 1957 USAF Service Magnesium Alloy Structure & Skin Convair XC - 99 First Modern Double Deck Airliner Capacity: 400 fully equipped troupes Consolidated Vultee Model 37 Proposed Civilian Version Pan Am ordered 15 before program cancellation
- 4. • Magnesium Alloys •Corrosion Resistant Alloys • Current Aircraft Applications • EFV • Automotive Growth • Flammability • Conclusions Magnesium Elektron Mg in Aerospace
- 5. Magnesium Casting Alloys MagnesiumCasting Alloy Families – Commonly used alloy systems employed today Al - Zn - Mn Zn - RE - Zr Ag - RE - Zr Y - RE - Zr EZ33 ZE41 ZE63 QE22 EQ21 WE43 WE54 Elektron 21 (EV31) Nd - Gd - Zn - Zr AZ81 AZ91 AZ92 AgAg -- RERE -- ZrZr early 1960searly 1960s YY -- RERE -- ZrZr late 1980slate 1980s Elektron21Elektron21 late 1990slate 1990s mid 1980smid 1980sAlAl -- ZnZn -- MnMn 1930s1930s ZnZn -- RERE -- ZrZr late 1940slate 1940s late 1960slate 1960s
- 6. Elevated Temperature Exposureon the Tensile Properties of Various Magnesium & Aluminum Alloys WE43A-T6 ELEKTRON 21 QE22A-T6 A356-T6 C355-T71 Tensile Yield Aluminium Data from ASM Metals handbook Vol 2 Revised March 28, 2005 0 10 20 30 40 50 0 100 200 300 400 500 600 Temperature, °F TensileStress(ksi) 0 10 20 30 40 50 0 100 200 300 400 500 600 Temperature, °F
- 7. • Magnesium Alloys •Corrosion Resistant Alloys • Current Aircraft Applications • EFV • Automotive Growth • Flammability • Conclusions Magnesium Elektron Mg in Aerospace
- 8. Mg Components onAircraft - Historical 1948 - 1954 • 4 tonnes of magnesium alloy - 10% of structural weight* • 1,900 lbs weight saving - Range extended by 190 miles* *Source: Aviation Week, 12th July 1948, P21 Convair BConvair B--3636 ““Magnesium OvercastMagnesium Overcast”” Past concern: Corrosion
- 9. Mg Components onAircraft - Historical B52 Stratofortress One of many brake applications Castings courtesy of Lite Metal Castings B-52s have been in service for almost 52 years, with many magnesium components lasting way beyond the initial design life. 1955 to Present Past concern: Corrosion
- 10. AZ92/91/81 Sand &Permanent Mold Castings Krueger Flaps AZ92 Castings Boeing 727 1,832 built between 1962 and 1984 Boeing 727 had 1200 magnesium part nos. including leading & trailing edge flaps, control surfaces, actuators, door frames, wheels, engine gear boxes, power generation components, structural items (not primary), and others. Past concern: Corrosion No Parts Rejected for:
- 11. Corrosion Comparison ofSome Magnesium & Aluminum Castings Alloys-Test Coupons - 100 200 300 400 500 600 700 800 900 1,000 1,100 ASTM B117 Salt Fog Corrosion Rate (mils penetration per year) C355 A356 A357 A201 A203 A206 WE43 WE54 AZ91E AZ91C ZE41 EZ33 Elektron 21 Al Alloys Mg Alloys WITH SPEC LIMITS AMS specification limits
- 12. Corrosion Test Cylindersafter ASTM B117 Salt Fog Testing Corrosion Resistant Alloys: WE43 AZ91E Standard Purity Alloy: AZ91C WE43 AZ91E AZ91C
- 13. AZ91C vs. AZ91E Tested10 days to ASTM B117 Casting approximately 24” x 16” x 4” Salt Fog Corrosion Improvement
- 14. • Magnesium Alloys •Corrosion Resistant Alloys • Current Aircraft Applications • EFV • Automotive Growth • Flammability • Conclusions Magnesium Elektron Mg in Aerospace
- 15. AZ92A Castings Thrust Reverser Cascade Casting Found on: 737 747 757 767 providedby Consolidated Foundries
- 16. AZ91E Castings Lycoming 540 Series Castingscourtesy of Lite Metal Castings Extra 300 Piper Chieftain Piper Comanche
- 17. Sikorsky CH53DSikorsky CH53D SeaStallionSea Stallion 630 lbs. (285 kgs.)630 lbs. (285 kgs.) AZ91E Castings
- 18. ZE41 Castings Sikorsky UH60 Family(Blackhawk) Transmission designed in ZE41 for ½ hour dry run capability
- 19. ZE41 Castings BoeingBoeing CH47 ChinookCH47Chinook Multiple Drivetrain CastingsMultiple Drivetrain Castings CH-47D
- 20. ZE41 Castings BoeingBoeing AH64AH64 ApacheApache AH-64DLongbow AH-64C
- 21.
- 22. ZE41 Castings Pratt &Whitney Canada PWC 100 Series Turboprop Operating on >1900 aircraft Bombardier Q Series Dash 8 BAe ATP PW150 Series – 7000 shp class
- 23. ZE41 Castings RollsRolls--Royce AllisonAERoyce Allison AE-- 30073007 EMB ERJ CITATION X GLOBAL HAWK Over 900 ERJ’s produced since 1995
- 24. ZE41 Castings Pratt &Whitney Canada PW535 Turbofan PW500 Family: 2,500 to 4,000 lbs Thrust Cessna Citation Excel
- 25. ZE41 Castings Pratt &Whitney Canada PW535Pratt & Whitney Canada PW535 TurbofanTurbofan PW500 Family: 2,500 to 4,000 lbs ThrustPW500 Family: 2,500 to 4,000 lbs Thrust provided by Fansteel Wellman Dynamics
- 26. ZE41 Castings Hamilton SundstrandHamiltonSundstrand F16 AMADF16 AMAD 4000th F-16 Casting mold containing ~ 100 cores
- 27. QE22 Castings BAE 146with ALF 507s
- 28. QE22 Castings General Electric F110Engine F-16C/D ACCESSORY DRIVE GEARBOX General Dynamics F16
- 29. WE43 Castings MD500 UpgradeGear Box MD 600 Gear Box MD500 / MD 600
- 30. WE43 Castings SikorskyS92Sikorsky S92 Main transmission castings are in WE43 Believed to be 10 castings in total
- 31. WE43 Castings TILT-AXIS GEARBOX (20”x 20” x 20”, 25.5#) COVER QUILL QUILL Bell Agusta 609 First flight March 7, 2003
- 32.
- 33. WE43 Castings F-35A Air Force F-35B Marines F-35C Navy LockheedMartin Single Engine Joint Strike Fighter planned production ranges from 3,000 to 6,000 aircraft numerous participating countries
- 34. Elektron 21 CastingsMilitary Rotary Aircraft - Attack Elektron 21 has been selected for use on seven drive train castings including the main transmission housing Boeing Mesa has selected Northstar Aerospace as the source for the Block III transmission. BoeingBoeing AHAH--64D64D ApacheApache Twin Engine Medium Attack Helicopter AH-64D
- 35. • Magnesium Alloys •Corrosion Resistant Alloys • Current Aircraft Applications • EFV • Automotive Growth • Flammability • Conclusions Magnesium Elektron Mg in Aerospace
- 36. Expeditionary Fighting Vehicle- EFV The EFV will be capable of transporting 18 Marines and a crew of three over water at speeds of 29 miles an hour; the design uses a planing hull propelled by two water jets. On land, it will achieve speeds of 45 miles an hour, with cross-country mobility equal to an M1 Abrams tank.
- 37. Elektron 21 Castings 1PTM main housing Elektron 21 2 HYD. Output cover Elektron 21 3 PTM center retainer Al Alloy 4 water jet output housing Elektron 21 5 water jet planet cover Elektron 21 6 water jet wing cover Elektron 21 7 main drive input housing Elektron 21 8 main drive center housing Elektron 21 9 right trunion cover Elektron 21 10 right main output Elektron 21 11 left main output adapter ZE41 12 left main output ZE41 13 left trunion cover Elektron 21 15 controls cover AZ91E 16 pump control housing Elektron 21 17 controls cover AZ91E PTM=power transfer module (converts from driving water jets to tracks) EFV Transmission Castings PTM 7 10 8 1.2 m 12 13 X4560 TRANSMISSION 11 15 4 6 3 1 0.8 m 2 5 copy of opposite end 16 17
- 38. 1st EFV SDDTransmission Completion July 24th, 2002
- 39. • Magnesium Alloys •Corrosion Resistant Alloys • Current Aircraft Applications • EFV • Automotive Growth • Flammability • Conclusions Magnesium Elektron Mg in Aerospace
- 40. Major Magnesium BasedAuto Products 3rd Row Seat Frames Bucket Seat Frames Steering Column Brackets Instrument Panel Transfer Case Transmission Case Header Bow Center Console Front End Structures Engine Cradle Cam Covers Information from Meridian Technologies
- 41. • GM FullSized Vans - Savana & Express - up to 26,3 kg • Audi A6-2,8 Multitronic - up to 20,31 kg • GM Minivans - Safari & Astro - up to 16,7 kg • Ford F-150 Truck - 14,9 kg • VW Passat, Audi A4 & A6 - from 13,6 to 14,5 kg • Audi TT - from 11,48 to 12,51 kg • Porsche Boxster Roadster - 9,9 kg • Buick Park Avenue - 9,5 kg • Alfa Romeo 156 - 9,3 kg • Jaguar XJ - 8,7 kg • Golf & Polo - from 8,16 to 9,19 kg • DaimlerChrysler SLK Roadster - 7,7 kg Major Platforms Using Magnesium A Division of Luxfer Group Magnesium Elektron Magnesium Die Castings Alloys
- 42. World Demand ForMagnesium 0 100 200 300 400 500 600 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 Year '000 tonnes Gain of 280,000 metric tonnes of magnesium (>600m lbs) since early 1990’s Magnesium Industry Growth WORLD DEMAND FOR MAGNESIUM A Division of Luxfer Group
- 43. • 85% ofall die castings manufactured are used for automotive components. Western World Demand For Die Castings 0 50 100 150 200 250 300 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 Year '000 tonnes North America Europe Pac Rim & Others Magnesium Die Casting FORECAST GROWTH IN AUTOMOTIVE A Division of Luxfer Group
- 44. A Division ofLuxfer Group Automotive Trends Elektron AJ62 • Mg/Al Composite Engine Block • 10 kg weight saving. • Now in full production - 450,000 units per annum.
- 45. • Magnesium Alloys •Corrosion Resistant Alloys • Current Aircraft Applications • EFV • Automotive Growth • Flammability • Conclusions Magnesium Elektron Mg in Aerospace
- 46. How To StartA fire ! FACTS • Must Reach Melting Point – (Pure Magnesium = 12000F 6500C) • Must Sustain Heat Source – to overcome conductivity • Must Have Oxygen • Solid magnesium is not easy to burn • Magnesium powders can be . designed & used in flares • Aluminium powder is used in . propulsion systems …
- 47. 0 200 400 600 800 1000 1200 1400 0 120 240 360 480 600 720 840 960 1080 1200 1320 1440 1560 1680 1800 1920 Time (s) Temperature(C) 0 500 1000 1500 2000 2500 Temperature(F) 50mm 100mm 150mmFlame 19000F (10000C+) Flame test – Elektron 21
- 48. Time to Ignitionwith 19000F (10000C+)Flame 0 10 20 30 40 1 2 3 4 TIMETOINITIATEBURNING(Mins) AZ91 ZE41 WE43 Elektron 21
- 49. FAATC Tests -Preliminary Mg Burning Characteristics • FAR 25.853 Appendix F Part 2 – Seat Cushion test – 1900F flame with heat flux of 10.5 Btu/ft2/sec – 2 minute exposure plus 5 minute dwell time • Tests on Magnesium exceeded 2 minutes – flame on 4 - 5 minutes, until melted & beyond
- 50. FAA Test data- FAR 25.853 Part 25, Appendix F, Part 2 Modified Seat Cushion Test WE43, Elektron 21 - Did not Burn when melted or self extinguished AZ31 - Burned when melted Part 2 Seat Cushion test used as severe condition for preliminary Mg Alloy data.
- 51. Behaviour of ElektronWE43 versus AZ91* * Courtesy EADS/Grenoble University regular surface with appearance of cracks with oxides therein Elektron WE43 non-cracked region cracked region O Mg Y non-cracked region cracked region O Mg Ycracked region T ignition = >12750F EDX analysis AZ91 T ignition = 10750F
- 52. Airbus commissioned testsat an FAA approved laboratory. Industrial flame test according to IGC 04.24.106, corresponding to US FAA, CS25 / JAR 25 / FAR 25§25-853 Airbus Commissioned FAA Flammability Tests
- 53. Both Elektron WE43and Elektron 21 tested, 2mm and 6mm (0.08 inch & 0.25 inch) thick cast sheets. With and without HAE surface treatment. 0°, 45° and 90° angle flame impingement. Elektron 21T6, horizontal flammability test WE43T6, vertical flammability test All tests passed Airbus Commissioned FAA Flammability Tests
- 54. • Magnesium Alloys •Corrosion Resistant Alloys • Current Aircraft Applications • EFV • Automotive Growth • Flammability • Conclusions Magnesium Elektron Mg in Aerospace
- 55. Conclusions • Many successfulpast & present aircraft applications of Magnesium • Past concerns were mainly corrosion, few for Fire • Solid Magnesium requires significant heat to melt • Melting point is the same as Aluminium • Melting must occur before opportunity to burn • Newer alloys (WE43, Elektron 21) are more “flame resistant” than older alloys • Magnesium used in Aircraft Engines. More recently , resurgence of interest in Magnesium for interior applications to save weight
- 56. • Magnesium Alloys •Corrosion Resistant Alloys • Current Aircraft Applications • EFV • Automotive Growth • Flammability • Conclusions Magnesium Elektron Mg in Aerospace • One Last Thing
- 57. Airbus Internal RegulationChange Airbus are evaluating Elektron 21 and Elektron WE43, both in investment cast and sand cast form, for use on their commercial aircraft.
- 58. Airbus Internal RegulationChange These alloys are no longer banned on the A380 (except for the primary structure).
- 59. Magnesium Elektron Mgin Aerospace The End Thank you for your attention