Abstract: Hybrid articles comprising a molded mixture of a light metal alloy and a polymer are formed by processing (including co-molding and co-extruding) the metal in a semi-solid state at a high shear rate and the polymer in a melt processable state. For example, magnesium alloy particles in a thixotropic condition are mixed with particles or globules of the polymer and molded into a hybrid metal-containing and polymer-containing body. The proportions of magnesium and polymer may be varied substantially depending on the desired properties of the hybrid article. In another embodiment the light metal and polymer may be co-extruded as two or more distinct layers into a solid or hollow hybrid body.

Abstract: A method for attaching an aluminum panel to a magnesium panel via a self-piercing rivet. The method includes positioning the aluminum panel and the magnesium panel together with the magnesium panel supported on an anvil having a cavity therein. The magnesium panel is spot heated at the locale of the anvil, and then the self-piercing steel rivet is punched through the steel panel and only partway into the magnesium panel, to displace the magnesium panel into the cavity. The heating of the magnesium improves the ductility so that the self-piercing rivet is accepted without undue strain on the magnesium material. The interface between the steel rivet and the magnesium panel is concealed between the aluminum panel and the magnesium panel to thereby protect the interface between the steel material of the rivet and the magnesium panel from exposure to the environment.

Abstract: A magnesium alloy comprising up to about six weight percent zinc and up to about one weight percent cerium may be hot worked to produce an intermediate or final alloy workpiece that exhibits enhanced ductility and strength at room temperature. The addition of zinc and a small amount of cerium may affect the magnesium alloy by increasing strength and ductility, and improving the work hardening behavior.

Abstract: A magnesium alloy comprising up to about one weight percent of cerium may be hot worked to produce an intermediate or final alloy workpiece that exhibits enhanced ductility at room temperature. The addition of a small amount of cerium may affect the magnesium alloy by reducing yield strength, refining grain size, and improving the work hardening behavior. Recrystallization during hot deformation of the rare earth containing magnesium material alters the texture of the alloy and orients the grains in a manner that favors basal slip activity. The alloy thus deforms at room temperature by a combination of twinning and slip mechanisms.

Abstract: Magnesium or magnesium alloy components having galvanic corrosion protection isolators secured in place by metallurgical bonding during casting of the magnesium or magnesium alloy component. The isolators are formed of materials that are characterized by an absolute potential difference that is between that of magnesium and a contacting metallic component.

Abstract: An instrument panel beam includes an elongated main member having a bent tubular configuration, and a plurality of structural supports connected to the member. The beam is formed of a lightweight material, such as a magnesium or aluminum alloy. The beam is preferably constructed utilizing a die-cast process, wherein at least a portion of the member is overmolded by each support so as to cooperatively form a soldered region therebetween.

Abstract: A method for bending magnesium alloy tubes. The method includes heating the tube at moderate temperature in the range of about 100° C. to 200° C., and bending the tube to a bend angle or forming the tube to a desired shape.

Abstract: The present invention involves a method to produce crush zones in aluminum structures using controlled application of retrogression heat treatment. Selected areas of a tubular rail are retrogression heat treated to locally lower the tensile yield strength. As a result, during a crash event, initial deformation is localized in the crush zone enabling the crush pattern to be designed directly into the structure.

Abstract: The present invention involves a method to produce crush zones in aluminum structures using controlled application of retrogression heat treatment. Selected areas of a tubular rail are retrogression heat treated to locally lower the tensile yield strength. As a result, during a crash event, initial deformation is localized in the crush zone enabling the crush pattern to be designed directly into the structure.

Abstract: The present invention provides a process for forming aluminum alloy hydroformed structures for automotive vehicles at low cost. The process continuously casts molten aluminum alloy into aluminum alloy strip material preferably followed by continuously warm rolling the strip material into aluminum alloy sheet material. The sheet material is formed into one or more aluminum alloy tubes and the tubes are hydroformed into the desired automotive vehicle structure.

Abstract: The present invention provides a process for forming aluminum alloy hydroformed structures for automotive vehicles at low cost. The process continuously casts molten aluminum alloy into aluminum alloy strip material preferably followed by continuously warm rolling the strip material into aluminum alloy sheet material. The sheet material is formed into one or more aluminum alloy tubes and the tubes are hydroformed into the desired automotive vehicle structure.

Abstract: A family of die castable, creep-resistant magnesium alloys has been developed for high-temperature structural applications such as automotive engines and transmission cases. These alloys contain between 3% and 6% aluminum, 1.7% and 3.3% calcium, and up to 0.2% strontium. They have demonstrated 25% greater tensile and compressive creep resistance than AE42, a commercial aluminum, rare earth containing magnesium alloy, and corrosion resistance as good as AZ91D. These alloys are estimated to cost less than AZ91D and have good castability in metal molds as used in permanent mold casting and die casting.

Abstract: A magnesium based alloy exhibiting superior elevated-temperature properties such as creep resistance and tensile strength and die castability such as reduced hot-cracking and die-sticking, contains about 2 to 9 wt. % aluminum, 6 to 12 wt. % zinc, 0.1 to 2.0 wt. % calcium, optionally 0.2 to 0.5 wt. % manganese, and the balance comprising magnesium. The alloy includes the intermetallic compound Mg--Al--Zn--Ca at the grain boundaries of the magnesium crystals. The alloy according to this invention may have a creep extension of less than about 0.6% at the tensile stress of about 35 MPa and the temperature of about 150.degree. C., and a tensile yield strength of at least 110 MPa at the temperature of about 150.degree. C. The alloy is particularly useful in die casting applications.