Wheel Magnesium Alloy Composition for Low-Temperature Spinning
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Solution Overview
Problem
Magnesium alloys exhibit low strength and plasticity at room temperature, limiting their application in industries like automobile and aerospace, and existing high-strength alloys with high room temperature plasticity are costly and complex to produce, requiring advanced processing equipment and rare earth elements.
Innovation Solution
A magnesium alloy with a composition of Al: 2-3.0wt.%, Zn: 0.5-1.0wt.%, Mn: 0.3-0.5wt.%, Ce: 0.15-0.3wt.%, and La: 0.05-0.1wt.% is developed, allowing for low-temperature spinning and forming with improved mechanical properties, using a smelting and extrusion process that includes stress-relief treatment and air cooling, reducing the need for expensive rare earth elements and complex processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional forging process is used to manufacture wheel hubs, then spokes and wheel rims can be obtained, but super-large tonnage forging equipment is needed, resulting in high processing risk, large metal loss and high cost
Solution Approach 1:
The wheel hub manufacturing process is divided into two separate operations: forging the hub body and spinning the wheel rims. This segmentation allows each process to use appropriately sized equipment, eliminating the need for super-large tonnage forging equipment while reducing processing risk and metal loss.
2Productivity
If spinning process is used to form wheel rim, then metal utilization rate is improved and forging equipment tonnage is reduced, but the die is not easy to heat and the forging blank loses heat, requiring high low temperature formability
Solution Approach 1:
The alloy composition is specifically designed with Al (2-3.0wt.%), Zn (0.5-1.0wt.%), Mn (0.3-0.5wt.%), Ce (0.15-0.3wt.%), and La (0.05-0.1wt.%) to change the material parameters, enabling the magnesium alloy to maintain adequate formability at lower spinning temperatures without requiring excessive heating of the die or blank.
3Ease of operation
If ZK30 magnesium alloy is used for low temperature spinning, then excellent spinning performance is achieved, but preparation cost is high due to Zr element addition
Solution Approach 1:
The patent replaces expensive Zr elements with more cost-effective Al, Zn, Mn, Ce, and La elements in specific proportions. This substitution achieves comparable or better low-temperature spinning performance while significantly reducing alloy preparation cost, making the material more economically viable for mass production.
4Strength
If magnesium alloy with high room temperature plasticity is prepared by various methods, then plasticity is improved, but preparation cost increases and preparation complexity increases
Solution Approach 1:
The patent creates a composite alloy system combining Mg with Al, Zn, Mn, Ce, and La elements. This composite composition achieves high room temperature plasticity through synergistic effects of the alloying elements, avoiding complex preparation methods while maintaining excellent formability and mechanical properties.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The alloy achieves tensile yield strength of 190 MPa, tensile strength of 280 MPa, and elongation of over 15.8% at room temperature, while being cost-effective and suitable for mass production, with improved high-temperature oxidation resistance and simplified production requirements.
Implementation Method 1
the processes of cutting into blanks and peeling are also included before extrusion
Implementation Method 2
A method of preparing a magnesium alloy comprises the following steps: (1) batching, in terms of the mass percentage
Data Source
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AI summary
A magnesium alloy for wheels, comprising in mass percentage: Al: 2∼3.0wt.%; Zn: 0.5∼1.0wt.%; Mn: 0.3∼0.5wt.%; Ce: 0.15∼0.3wt.%; La: 0.05∼0.1wt.%, the balance is Mg. The magnesium alloy of the present invention takes Al element and Mn element as main alloying elements, supplemented by trace Ce and La elements as alloying process, and the nano-scale Mn-rich precipitated phase obtained during homogenization and the segregation of rare earth elements Ce and La at the interface and grain boundary of Mn-rich precipitated phase are used to inhibit the coarsening during extrusion and forging, so as to improve the strength and plastic deformation ability of the alloy.