Abstract: One exemplary embodiment includes a cast alloy including Al present in an amount of about 6.5 wt % to about 9.0 wt %; Sn present in an amount of about 1.0 wt % to about 3.0 wt %; Ce present in an amount of about 0 wt % to about 1.0 wt %; and, Mg comprising a balance of the alloy minus an amount of minor and trace elements wherein Mg is present at an amount of greater than about 85 wt %.

Abstract: One embodiment includes a wheel including a first portion including magnesium, the first portion including at least a rim; a second portion including aluminum; and an interface where the first portion and the second portion contact each other.

Abstract: The grain size of magnesium alloys is effectively refined and made smaller by the addition of a small amount of titanium. The effect of the reduction of grain size is often an improvement in the strength and processability of a cast magnesium alloy. Often less than about 0.1% by weight of titanium need be used. It may be preferred to incorporate the titanium with another alloying constituent (such as aluminum) for addition to a melt of a magnesium base alloy.

Abstract: Methods of extruding magnesium-based casting alloys are provided. The magnesium alloys have relatively high strength and castibility, as well as an improved ductility and extrudability for wrought alloy applications. The magnesium-based wrought alloy comprises aluminum (Al) of between about 2.5 to about 3.5 wt. %, manganese (Mn) of less than about 0.6 wt. %, zinc (Zn) of less than about 0.22 wt. %, other impurities of less than about 0.1 wt. %, and a balance of magnesium (Mg). The disclosure provides various methods of forming extruded structural components, including automotive components, and methods of forming such wrought alloys.

Abstract: A method of improving the corrosion resistance of magnesium alloy castings containing more than about 2 per cent by weight of aluminum is described. The method comprises: first selecting a casting process suitable for developing at least on the surface of the casting a microstructure comprising aluminum-depleted magnesium grains surrounded by an aluminum-rich layer and preferably incorporating at least some of an intermetallic compound based on the composition Mg17Al12; and second, heat treating at least the outer layer of the casting to promote additional intermetallic compound precipitation as required.

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: Methods of reducing corrosion between magnesium and another metal are disclosed herein. In one method, a corrosion protection material is cold sprayed at an interface formed between the magnesium and the other metal, the corrosion protection material including magnesium. In another method, a cladding layer is applied to heat affected areas of the magnesium and/or the other metal, at a welded joint, or combinations thereof.

Abstract: One embodiment includes a wheel including a first portion including magnesium, the first portion including at least a rim; a second portion including aluminum; and an interface where the first portion and the second portion contact each other.

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: Methods of extruding magnesium-based casting alloys are provided. The magnesium alloys have relatively high strength and castibility, as well as an improved ductility and extrudability for wrought alloy applications. The magnesium-based wrought alloy comprises aluminum (Al) of between about 2.5 to about 3.5 wt. %, manganese (Mn) of less than about 0.6 wt. %, zinc (Zn) of less than about 0.22 wt. %, other impurities of less than about 0.1 wt. %, and a balance of magnesium (Mg). The disclosure provides various methods of forming extruded structural components, including automotive components, and methods of forming such wrought alloys.

Abstract: A tin-containing magnesium-aluminum-manganese (Mg—Al—Mn) based alloy that provides a desired combination of strength and ductility so as to be particularly suited for structural applications. The alloy includes magnesium, aluminum, and manganese in combination and about 0.5% to about 3.5% tin. The tin addition improves strength without substantial loss of ductility.

Abstract: The grain size of magnesium alloys is effectively refined and made smaller by the addition of a small amount of titanium. The effect of the reduction of grain size is often an improvement in the strength and processability of a cast magnesium alloy. Often less than about 0.1% by weight of titanium need be used. It may be preferred to incorporate the titanium with another alloying constituent (such as aluminum) for addition to a melt of a magnesium base alloy.

Abstract: Durable elastomeric polyurea coatings can be applied to metal surfaces subjected to impacts and environmental corrosion. Corrosion resistance of the coatings, especially on magnesium alloy surfaces, is improved by incorporation of particulate inhibitor additives in the liquid polyurea precursor coating material. Examples of inhibitors include potassium dichromate, sodium dichromate, potassium permanganate, vanadium pentoxide, phosphorus anhydride, cerium oxide, lanthanum oxide, calcium oxide and sodium oxide.

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: 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.