Investigating new ultra-lightweight structural alloys

Lightweight components, that still confer the necessary strength, are advantageous for many applications in the automotive and aerospace sectors, with the potential to extend the range of electric vehicles, making them highly desirable as we seek to achieve net-zero. Magnesium is the lowest density metallic element used for commercial alloys, but they tend to have lower strength than Al alloys and their hexagonal crystal structure can make shaping components complex.

In this project, the potential of novel magnesium alloys reinforced by nanoscale precipitates to give exceptionally high specific strength will be assessed. One challenge of these alloys, is that their microstructures can age at room temperature, leading to properties that vary over time. Thus, creating stable microstructures that convey a combination of mechanical properties, including strength and fracture toughness, and corrosion resistance in service is key.

This project will make and characterise these novel lightweight Mg alloys, seeking to produce dual phase precipitate reinforced microstructures. It will involve X-ray analysis and electron microscopy techniques to characterise the microstructures produced and the study the effect of fabrication processes and thermomechanical processing. The mechanical properties, microstructural stability and corrosion resistance of the alloys will be tested and linked to the microstructure to determine their potential for structural applications.