Aeronautical Application of Wrought Magnesium
The aluminium alloys used today for aerospace applications are already optimised as far as aeronautical requirements are concerned, such as strength, fatigue and damage tolerance properties. Magnesium, with a density of only 65% of that of aluminium, could be a breakthrough technology in the aerospace industry if used for cost-efficient, low-weight components and airframe structures. However, to use this low weight material the mechanical and technological properties have to be improved.
The technological objective is a weight reduction of fuselage parts, systems and interior components of up to 35%. The strategic objectives are a 10% increase in the operational capacity, a 10% reduction in direct operating cost and a 10% reduction in the fuel consumption, and therefore a reduced environmental impact with regard to emissions and noise.
Description of the work
The technical focus of the university-driven proposal, AEROMAG, which has been prepared in close collaboration with the Network of Universities ‘EASN’, is the development of new magnesium wrought products (sheets and extrusions), which provide significantly improved static and fatigue strength properties. The strength properties of these innovative materials are required to be as high as AA5083 for non-structural applications and as high as AA2024 for aluminium alloys for secondary structure applications.
At first new alloys will be developed and existing alloys will be tested. Appropriate manufacturing (rolling, extrusion), forming and joining technologies require development, simulation and validation for the innovative material and application. Corrosion is a problem that needs to be solved with the newly adapted and environmentally friendly surface protection systems and advanced design concepts. Flammability will be addressed with the addition of chemical elements and special surface treatments. A further essential task is the development of material models and failure criteria for the prediction of forming processes, plastic deformation and failure behaviour of components. Finally, material-adapted design and the evaluation of structural behaviour will be investigated to close the process and development chain for aeronautic components.
Improved magnesium alloys; cost-efficient production routes for sheets and extrusions; a comprehensive material database; improved flammability behaviour; simulation tools and key parameters of forming processes; key parameters and properties of joining processes; environmentally friendly surface protection systems; definition of design rules; structural behaviour of magnesium components; weight specific cost analysis of typical components.
- Related Info
- Acronym: AEROMAG
- Contract No.: AST4-CT-2005-516152
- Total Cost: €3 834 660
- EU Contribution: €2 492 327
- Starting date: 01/03/2005
- Duration: 36 months
EADS Deutschland GmbH,
Corporate Research Center Germany
Tel: +49 89 607 20 888
Fax: +49 89 607 25 408
- EC officer :
Hans Josef von den Driesch
Tel: +32 2 296 0609
Fax: +32 2 296 6757
- EADS Deutschland GmbH DE
- EADS CCR FR
- All-Russia Institute of Light Alloys RU
- Federal State Unitary Enterprise ‘All-Russi AN
- Scientific Research Institute of Aviation Materials’ RU
- University of Patras GR
- University of Thessaly GR
- Institut National Polytechnique de Grenoble FR
- Ecole Nationale Supérieure d’Arts et Métiers (ENSAM), Centre d’Enseignement et de Recherche d’Aix-en-Provence FR
- Technische Universität Wien AT
- Technion - Israel Institute of Technology IL
- Università di Napoli ‘Federico II’ IT
- Salzgitter Magnesium-Technologie GmbH DE
- Otto Fuchs KG DE
- ALONIM Holdings Agricultural Cooperative Ltd. IL
- Eurocopter S.A.S. FR
- Airbus Deutschland GmbH DE
- Alenia Aeronautica S.p.A. IT
- Palbam Metal Works IL