Magnesium wrought alloy having improved extrudability and formability
In one aspect, the invention provides a magnesium-based casting alloy having relatively high strength and castibility, as well as an improved ductility and extrudability for wrought alloy applications. The magnesium-based wrought alloy comprises aluminum (Al) of between about 2.5 to about 4.0 wt. %, manganese (Mn) of less than about 0.6 wt. %, zinc (Zn) of less than about 0.3 wt. %, other impurities of less than about 0.1 wt. %, and a balance of magnesium (Mg). The invention further provides methods of forming a wrought alloy component and automotive components formed therefrom.
1 . A metal alloy comprising:
aluminum (Al) from about 2.5 to about 3.5 wt. %; manganese (Mn) from about 0.2 to about 0.6 wt. %; zinc (Zn) less than about 0.3 wt. %; one or more impurities collectively less than about 0.1 wt. %; and a balance of magnesium (Mg).
2 . The metal alloy according to claim 1 , wherein said aluminum is about 3 wt. %.
3 . The metal alloy according to claim 1 , wherein said manganese is about 0.4 wt. %.
4 . The metal alloy according to claim 1 , wherein said composition comprises said aluminum (Al) of about 3 wt. %; said manganese (Mn) of about 0.4 wt. %; and said zinc (Zn) less than about 0.22 wt. %.
5 . The metal alloy according to claim 1 , wherein said one or more impurities comprise: silicon (Si) of less than about 0.01 wt. %, copper (Cu) of less than about 0.01 wt. %, nickel (Ni) of less than about 0.002 wt. %, iron (Fe) of less than about 0.002 wt. %, and one or more additional impurities of less than about 0.02wt. %.
6 . The metal alloy according to claim 1 , wherein the alloy has an elongation of greater than 8% at room temperature.
7 . The metal alloy according to claim 1 , wherein the alloy has an extrusion speed of greater than 305 mm per minute at 360° C.
8 . The metal alloy according to claim 1 , wherein the alloy has a yield strength of greater than about 165 MPa.
9 . The metal alloy according to claim 1 , wherein the alloy has an ultimate tensile strength of greater than about 230 MPa.
10 . The metal alloy according to claim 1 , wherein the alloy is corrosion resistant.
11 . A magnesium-based wrought alloy having a composition comprising:
aluminum (Al) of between about 2.5 to about 4.0 wt. %; manganese (Mn) and zinc (Zn) collectively present at less than about 1.0 wt. %; impurities collectively less than about 0.1 wt. %; and a balance of magnesium (Mg).
12 . The magnesium-based wrought alloy according to claim 11 , wherein the composition comprises aluminum (Al) from about 2.5 to about 3.5 wt. %; manganese (Mn) from about 0.2 to 0.6 wt. %; zinc (Zn) less than about 0.3 wt. %; one or more impurities of less than about 0.1 wt. %; and a balance of magnesium (Mg).
13 . The magnesium-based wrought alloy according to claim 11 , wherein the composition comprises manganese (Mn) from about 0.26 wt. % to about 0.6 wt.%; and zinc (Zn) less than 0.22 wt. %.
14 . The magnesium-based wrought alloy according to claim 11 above, wherein said one or more impurities comprise: silicon (Si) of less than about 0.01 wt. %, copper (Cu) of less than about 0.01 wt. %, nickel (Ni) of less than about 0.002 wt. %, iron (Fe) of less than about 0.002 wt. %, and one or more additional impurities of less than about 0.02 wt. %.
15 . The magnesium-based wrought alloy according to claim 11 , wherein said aluminum is about 3 wt. %.
16 . The magnesium-based wrought alloy according to claim 11 , wherein said manganese is about 0.4 wt. %.
17 . The magnesium-based wrought alloy according to claim 11 , wherein the composition comprises said aluminum (Al) of about 3 wt. %; said manganese (Mn) from about 0.4 wt. %; said zinc (Zn) less than about 0.22 wt. %; said one or more impurities of less than about 0.1 wt. %; and a balance of said magnesium (Mg).
18 . The magnesium-based wrought alloy according to claim 11 , wherein the wrought alloy has an elongation of greater than 8% at room temperature.
19 . The magnesium-based wrought alloy according to claim 11 , wherein the wrought alloy has an extrusion speed of greater than 305 mm per minute at 360° C.
20 . The magnesium-based wrought alloy according to claim 11 , wherein the wrought alloy has a yield strength of greater than about 165 MPa.
21 . The magnesium-based wrought alloy according to claim 11 , wherein the wrought alloy has an ultimate tensile strength of greater than about 230 MPa.
22 . The magnesium-based wrought alloy according to claim 11 , wherein the wrought alloy is corrosion resistant.
23 . A method of forming a wrought alloy element comprising:
forming a molten alloy material having a composition comprising aluminum (Al) of less than about 4.0 wt. %; manganese (Mn) and zinc (Zn) collectively present at less than about 1.0 wt. %; one or more impurities collectively less than about 0.1 wt. %; and a balance of magnesium (Mg), at a casting temperature;
cooling said alloy material to solidify; and
processing said solidified alloy material by deformation, thereby forming the wrought alloy element.
24 . The method according to claim 23 , wherein said composition comprises aluminum (Al) from about 2.5 to about 3.5 wt. %; manganese (Mn) from about 0.2 to about 0.6 wt. %; and zinc (Zn) less than about 0.3 wt. %.
25 . The method according to claim 23 , wherein said composition comprises manganese (Mn) from about 0.26 to about 0.6 wt. %; and zinc (Zn) less than about 0.22 wt. %.
26 . The method according to claim 23 above, wherein said one or more impurities comprise: silicon (Si) of less than about 0.01 wt. %, copper (Cu) of less than about 0.01 wt. %, nickel (Ni) of less than about 0.002 wt. %, iron (Fe) of less than about 0.002 wt. %, and additional impurities of less than about 0.02 wt. %.
27 . The method according to claim 23 , wherein said solidified alloy material comprises an ingot.
28 . The method according to claim 23 , wherein said solidified alloy material comprises a billet.
29 . The method according to claim 23 , wherein said casting temperature is greater than about 600° C.
30 . The method according to claim 23 , wherein said processing comprises a hot-working process.
31 . The method according to claim 23 , wherein said processing comprises a cold-working process.
32 . The method according to claim 23 , wherein said processing is selected from the group consisting of: extruding, rolling, bending, hydroforming, stamping, superplastic forming, gas forming, electromagnetic forming, and combinations thereof.
33 . The magnesium-based wrought alloy according to claim 23 , wherein said aluminum is about 3 wt. %.
34 . The method according to claim 23 , wherein said manganese is about 0.4 wt. %.
35 . The method according to claim 23 , wherein the composition comprises said aluminum (Al) of about 3 wt. %; said manganese (Mn) of about 0.4 wt. %; said zinc (Zn) less than about 0.22 wt. %; said one or more impurities of less than about 0.1 wt. %; and a balance of said magnesium (Mg).
36 . The method according to claim 23 , wherein said processed alloy material has an elongation of greater than 8% at room temperature.
37 . The method according to claim 23 , wherein said processed alloy material has an extrusion speed of greater than 305 mm per minute at 360° C.
38 . The method according to claim 23 , wherein said processed alloy material has a yield strength of greater than about 165 MPa.
39 . The method according to claim 23 , wherein said processed alloy material has an ultimate tensile strength of greater than about 230 MPa.
40 . The method according to claim 23 , wherein said processed alloy material is corrosion resistant.
41 . A component for use in a vehicle comprising a magnesium-based wrought alloy comprising aluminum (Al) of less than about 4.0 wt. %; manganese (Mn) and zinc (Zn) collectively present at less than about 1.0 wt. %; one or more impurities collectively less than about 0.1 wt. %; and a balance of magnesium (Mg).
42 . The component according to claim 41 , wherein said alloy comprises aluminum (Al) from about 2.5 to about 3.5 wt. %; manganese (Mn) from about 0.2 to 0.6 wt. %; and zinc (Zn) less than about 0.3 wt. %.
43 . The component according to claim 41 , wherein said alloy comprises manganese (Mn) from about 0.26 to about 0.6 wt. % and zinc (Zn) less than about 0.22 wt. %.
44 . The component according to claim 41 , wherein said one or more impurities comprise: silicon (Si) of less than about 0.01 wt. %, copper (Cu) of less than about 0.01 wt. %, nickel (Ni) of less than about 0.002 wt. %, iron (Fe) of less than about 0.002 wt. %, and additional impurities of less than about 0.02 wt.
45 . The component according to claim 41 , wherein said alloy forms a tubular structure.
46 . The component according to claim 41 , wherein said alloy forms a rolled structure.
47 . The component according to claim 41 , wherein said alloy forms an extruded structure.
48 . The component according to claim 41 , wherein said alloy forms an automotive part selected from the group consisting of frames, support members, cross-members, instrument panel beams, roof rails, engine cradles, transfer cases, and steering components.
49 . The component according to claim 41 , wherein said alloy forms a structure by one or more metal forming processes selected from the group consisting of bending, extruding, rolling, hydroforming, stamping, superplastic forming, gas forming, electromagnetic forming, and combinations thereof.
50 . A magnesium-based wrought alloy having a composition comprising:
aluminum (Al) of between about 2.5 to about 4.0 wt. %; manganese (Mn) and zinc (Zn) collectively present at less than about 1.0 wt. %; impurities collectively less than about 0.1 wt. %; and a balance of magnesium (Mg); wherein the wrought alloy has an elongation of greater than 8% at room temperature.
51 . The magnesium based alloy according to claim 50 , wherein the wrought alloy has a yield strength greater than about 165 MPa.
52 . The magnesium based alloy according to claim 50 , wherein the wrought alloy has an ultimate tensile strength of greater than about 230 MPa.
53 . A magnesium-based wrought alloy having a composition comprising:
aluminum (Al) of between about 2.5 to about 4.0 wt. %; manganese (Mn) and zinc (Zn) collectively present at less than about 1.0 wt. %; impurities collectively less than about 0.1 wt. %; and a balance of magnesium (Mg); wherein the wrought alloy having an extrusion speed of greater than 305 mm per minute at 360° C.
54 . The magnesium based alloy according to claim 53 , wherein the wrought alloy has a yield strength greater than about 165 MPa.
55 . The magnesium based alloy according to claim 53 above, wherein the wrought alloy has an ultimate tensile strength of greater than about 230 MPa.