Chip ignition in research on high-speed face milling AM50A magnesium alloy
The ignition of magnesium alloy chips is a problem during high speed dry machining in industry. It should be avoided in the practical production. Many factors including machining environment, material composition, tool geometry, cutting parameters etc. can influence the cutting processes. Among these factors, cutting parameters is one of most important elements to induce the ignition of magnesium alloys. AM50A is a commercial magnesium alloy which is widely used in industry. However, very few reports about the ignition conditions of AM50A magnesium alloy are available. In this paper, we investigated the ignition conditions of AM50A magnesium alloy at different cutting parameters. The relationship between ignition conditions and chip morphologies was further explored. The macro morphologies of the chips were observed by optical microscope and the micro structure were obtained by scanning electron microscope (SEM). It is found that the macro morphologies of chips can be characterized into powdered chip, tubular helical chip, acicular helical chip, and long belt chip, which correspond to the different ignition conditions. The powdered chips and acicular spiral chips are easily ignited. They have thinner lamellar thickness compared to the other two types of chips. These results may be used to analyze cutting process and prevent the chip ignition in dry machining magnesium alloy.
Magnesium and its alloys applications in automotive industry
The objective of this study is to review and evaluate the applications of magnesium in the automotive industry that can significantly contribute to greater fuel economy and environmental conservation. In the study, the current advantages, limitations, technological barriers and future prospects of Mg alloys in the automotive industry are given. The usage of magnesium in automotive applications is also assessed for the impact on environmental conservation. Recent developments in coating and alloying of Mg improved the creep and corrosion resistance properties of magnesium alloys for elevated temperature and corrosive environments. The results of the study conclude that reasonable prices and improved properties of Mg and its alloys will lead to massive use of magnesium. Compared to using alternative materials, using Mg alloys results in a 22% to 70% weight reduction. Lastly, the use of magnesium in automotive components is increasing as knowledge of forming processes of Mg alloys increases.
The Paths and Strategies for Increased Magnesium Applications in Vehicles
The use of magnesium in motor vehicles today and in future depends on numerous technical and economical factors, though the cost factor is essential. How might use of magnesium in vehicles develop, what prerequisites are necessary, what R&D efforts are required These questions will be addressed as follows based on component and project examples. The main focus of the current magnesium applications can be seen in the drive train and in the interior. In the short term, these applications will be further expanded: doubling the amount is feasible. This will be supported by the currently developed Mg alloys with extended application potential (creep resistance). Mg components in the body, Mg-sheets and Mg-extrusions applications will appear initially in niche-market and premium vehicles. This can prepare the way for and eventually lead to greater use of Mg in volume-production models as part of a multi-material design concept. The essential prerequisites for such increased use of magnesium will be discussed.