A new method to lightweight and improve strength to weight ratio of magnesium by creating a controlled defect

Abstract

Magnesium-based materials are the most sought-after metallic materials for weight sav-ing applications. Its low density (~33% lighter than aluminum) makes it an ideal choice foraerospace, space, sports, automobile and electronic industries. Magnesium based compo-nents can be even lighter if these components are manufactured hollow. However, studieson the structural integrity of hollow magnesium-based components are limited and hence,this study documents the structural stability of hollow magnesium-based components. Cen-tralized cylindrical holes (1, 1.5, 2 and 3 mm in diameter) were drilled in 8 mm diametermagnesium samples synthesized by disintegrated melt deposition followed by hot extru-sion. The effects of these centralized hole on the physical and compression properties werethen investigated. Compression test results demonstrated a significant increase in the com-pressive yield strength (~62%) and ultimate compressive strength (~11%) for the 1.5 mmdrilled magnesium sample when compared to undrilled monolithic magnesium. Further, thestrength (yield and ultimate) to weight ratio was higher for all the drilled samples comparedto pure magnesium. These results present an opportunity to light weight magnesium-basedcomponents using a controlled defect while improving or maintaining the overall compres-sive response of the material. Using Finite Element Analysis, an optimum drill diameter wasalso calculated which can be used as a foundation for future studies. © 2020 The Authors.