Thixomolding is a method of molding semi-solid magnesium alloy pellets using equipment and processing methods similar to injection molding. Its commercial growth has been driven by its technical advantages, including enhanced precision, environmental cleanliness, and the ability to produce complex 3D shapes with high yields and minimal waste.

Three types of thermal treating processes are commonly applied to magnesium alloys, including annealing, solution heat treatment, and precipitation, or aging.

The key obstacle to industrial scale magnesium rolling is the element’s inherently poor formability at room temperature. To address this challenge, the search is on for new magnesium alloys that feature improved formability along with novel rolling techniques. This article describes R&D activities at CanmetMaterials aimed at expanding manufacturing capabilities of magnesium-based sheet materials for future applications in transport vehicles.

An in-situ annealing technique combined with electron backscatter diffraction was used to characterize the microstructural evolution of ZE20 magnesium alloy as a function of temperature. This work sets the stage for future experiments to understand and control the recrystallization behavior of commercial alloys.

This case study reviews the considerations in using magnesium thermal spray surfacing to repair a hydraulic pump pad.

This article presents a broad overview of key annealing processes such as recovery, recrystallization, and grain growth in magnesium and its alloys. It explores the role of recovery in recrystallization behavior, evolution of recrystallization microstructure and texture, current understanding of grain coarsening in magnesium alloys, and concludes with a perspective on future research.

Computational thermodynamics and CALPHAD modeling prove useful for selecting and developing new magnesium alloys. This article summarizes an ongoing effort to establish a scientific foundation of computational thermodynamics and kinetics of magnesium alloys to achieve accelerated design and optimization of these alloys for weight reduction in the transportation industries.

Thixomolding is an environmentally clean and safe commercial process for semi-solid injection molding of magnesium alloys. The process is similar to plastic injection molding but with higher temperature and faster shot velocity. This article reviews advantages and applications of the process and future outlook for it.

The application potential of magnesium alloys as lightweight structural materials in aerospace and especially inside the aircraft cabin are hindered by their high surface reactivity at increased temperatures with particular concerns of ignition and flammability during a potential contact with a flame or other heat source. This article describes global efforts to develop ignition-resistant and nonflammable magnesium alloys. A widely explored avenue involves microalloying magnesium with rare earth metals and other elements having a high affinity to oxygen. As demonstrated by experimental alloys, this approach allows shifting the ignition temperature well above the liquidus, not only easing requirements on protective atmospheres during liquid-state processing, but also increasing the safety margin for possible aerospace applications.

Understanding both the origin and procedures for removing inclusions in magnesium alloys results in castings with enhanced mechanical and corrosion properties. This article provides an overview of typical inclusions found in magnesium and its alloys, various techniques used to determine inclusion content, and methods employed to reduce inclusions and their influence on properties.

This article reports on a study to better understand the integrity and microstructure of extrusion welding in a magnesium alloy (AM30) hollow section extrudate using light optical microscopy. The article is based on the entry that won the prestigious Jacquet-Lucas Award for Best in Show at the 2013 International Metallographic Contest.

Self-pierce riveting is a candidate for joining magnesium alloy sheet, extrusions, and castings in automotive applications. This article evaluates the fatigue performance of magnesium lap joints held together by laser-assisted self-piercing rivets (SPR) with and without the addition of adhesives.