A new method to lightweight and improve strength to weight ratio of magnesium by creating a controlled defect

Abstract

Magnesium-based materials are the most sought-after metallic materials for weight saving applications. Its low density (∼33% lighter than aluminum) makes it an ideal choice for aerospace, space, sports, automobile and electronic industries. Magnesium based components can be even lighter if these components are manufactured hollow. However, studies on the structural integrity of hollow magnesium-based components are limited and hence, this study documents the structural stability of hollow magnesium-based components. Centralized cylindrical holes (1, 1.5, 2 and 3 mm in diameter) were drilled in 8 mm diameter magnesium samples synthesized by disintegrated melt deposition followed by hot extrusion. The effects of these centralized hole on the physical and compression properties were then investigated. Compression test results demonstrated a significant increase in the compressive yield strength (∼62%) and ultimate compressive strength (∼11%) for the 1.5 mm drilled magnesium sample when compared to undrilled monolithic magnesium. Further, the strength (yield and ultimate) to weight ratio was higher for all the drilled samples compared to pure magnesium. These results present an opportunity to light weight magnesium-based components using a controlled defect while improving or maintaining the overall compressive response of the material. Using Finite Element Analysis, an optimum drill diameter was also calculated which can be used as a foundation for future studies.

Keywords

• Magnesium
• Disintegrated melt deposition
• Drilling
• Compressive properties
• Microstructure
• Simulation