Project to investigate magnesium in transport

Paul Boughton
Madrid Institute of Advanced Studies in Materials (IMDEA Materials), which is part of a strategic national consortium, is to research new magnesium-based transport technologies.

The MAGNO programme is a national consortium with a total budget of EUR30million over four years, consisting of 12 companies (four corporations and eight small and medium-sized enterprises) and 11 technology centres. It has been set up to promote and develop new technologies based on magnesium alloys. This CENIT (a Spanish acronym standing for Strategic National Consortium for Technical Research) is led by the Antolín Group, a leading multinational company that designs and manufactures car interior components and modules. The high-tech investment programme will give a boost to the metal industry in Spain, as well as making the country one of the leaders in an expanding future market.

IMDEA Materials will contribute to the consortium by carrying out research aiming to improve the mechanical behaviour at high temperature and high strain rate (shock conditions) of currently used cast and forged magnesium alloys by optimising casting processes and by developing novel alloys with enhanced mechanical performance.

At a time of record-breaking oil prices, light transport is no longer a luxury but a necessity. The saving in fuel would not only ease the strain on people's wallets, it would also significantly reduce emissions, with the resulting benefit for the environment.

Magnesium is one of the lightest metals. Its low density of 1.7g/cm3 makes it a key material in reducing the weight of cars and it could replace certain parts made of steel (7.8g/cm3) or aluminium (2.7g/cm3). Moreover, it is found in abundance in the Earth's crust and is easy to recycle and machine. Its specific mechanical resistance is excellent, even exceeding that of steel.

Magnesium was first isolated in 1808 by Sir Humphrey Davy. Due to its high flammability in powder form, until the end of the 19th century it was used exclusively to produce artificial light or as a photographic flash. However, its use soon extended to the transport industry and by 1939 the Volkswagen Beetle included 20kg of magnesium. Today, China is the largest producer of magnesium in the world and production costs have reduced dramatically, now being comparable to aluminium.

However, large-scale commercial use of magnesium in consumer vehicles is still some way off, as its mechanical resistance to high temperatures and corrosion has still not been improved sufficiently. For this reason, magnesium cannot be used to manufacture parts located on the vehicle exterior or in areas close to the engine. Furthermore, at present most parts are made by casting because, due to its hexagonal structure, magnesium is difficult to shape.

For more information, visit www.imdea.org