Due to their high specific strength, magnesium alloys are promising materials for further lightweighting in mobility applications. In contrast to casting and forming processes, additive manufacturing methods allow high degrees of geometrical freedom and can generate significant weight reductions due to load-specific part design. In wire arc additive manufacturing processes, large parts can be produced with high material utilization. Process-inherent high melt temperatures and solidification rates allow for the use of magnesium alloys which are otherwise complicated to process; this enables the use of unconventional alloying systems. Here, we report the development of a Mg-Al-Zn-Ca-rare earth alloy for wire arc additive manufacturing (WAAM). Compared to parts made of commercially available filler wire, the newly developed alloy achieves a higher strength (approx. +9 MPa yield strength, +25 MPa ultimate tensile strength) in WAAM.

Standard ultrasonic thickness measurements require the sound velocity of the sample to be known and vice versa. We present a method, which we have termed combined mode local acoustic spectroscopy (CoMLAS) for simultaneously determining a plate's thickness and sound velocities without requiring such a priori knowledge. It is based on a combination of three guided wave modes sustained by a plate at discrete frequencies, which we generate and detect using laser ultrasound. We use a pulsed laser that is shaped into a periodic line pattern on the sample's surface to generate elastic waves and measure the response at the pattern's center with a vibrometer. The surface acoustic wave mode produces an interference peak in the response spectrum at the frequency corresponding to the wavelength matching the pattern line spacing. By limiting the total size of the excitation pattern, we can simultaneously generate two zero-group-velocity plate resonances, providing two additional peaks in the spectrum. The plate's local thickness and longitudinal and transverse sound velocities are calculated from the peak frequencies. We demonstrate the feasibility of CoMLAS on steel and aluminum sheets with a thickness of around 2mm by resolving thickness steps and temperature-induced changes in the sound velocities. Using numerical simulations and control experiments, we provide insights into the method's accuracy and limitations. The choice of excitation pattern, the method's sensitivity, and the influence of sample inhomogeneity and anisotropy are discussed. CoMLAS does not require scanning mechanics and provides local plate properties. The results shown are achieved with low-energy lasers and signal averaging. Considerations on signal-to-noise ratio indicate that a realization with available lasers of higher energy will enable single-shot measurements. This qualifies the method for use on moving samples in an industrial environment.

Aluminum scrap is often contaminated with steel parts, leading to accumulation of Fe in recycled Al alloys. Consequently, low limits for Fe in Al wrought alloys are difficult to meet by recycling without dilution with primary Al. Wrought alloys with a higher tolerance for Fe could help overcome this problem and improve the sustainability of Al wrought products. Here we study the effects of increasing the Fe content in EN AW-6060, 6005A, and 6082 from 0.2 to 0.7 wt pct. The microstructure and mechanical properties of the alloys after extrusion and artificial ageing are compared to the standard alloys. We found that 6082 is more tolerant to above-standard Fe contents than 6005A, which in turn is more tolerant than 6060: the strength of the 6082-based alloy with increased Fe content is comparable to that of standard 6082 and the elongation at break is increased. In contrast, the artificial ageing potential of the 6060-based alloy with more Fe is drastically reduced compared to 6060. This data and literature values show that the effective Si content is a good overall predictor of alloy strength. Effective Si is not bound in AlFeSi-type phases and is available for precipitation hardening. Additional effects of increased Fe levels are discussed.

The low mass and high specific stiffness of Mg alloys make them particularly interesting as means of transportation. Due to further desirable properties, such as good machinability and excellent castability, Mg alloys have gained acceptance as castings in high-volume applications, such as gearbox housings and automotive steering wheels. However, in forming processes, such as extrusion and forging, Mg alloys find little to no industrial use at the moment. The reasons for this are their poor formability, which is reflected in limited processing speeds and low ductility, and their modest mechanical performance, compared to competing materials, such as Al alloys and high-strength steels. Much research is being conducted worldwide on high-strength Mg alloys, most of which rely on high levels of rare earths, making these materials both ecologically and economically questionable. Here, it is shown that high yield strengths (>300 MPa) can be achieved in the Mg–Al–Ca system while maintaining good ductility, using only low-cost elements. The investigations have shown that these properties can be adjusted over broad alloy compositions, which greatly simplifies both the processing and recyclability.