Material behaviour along the wire production process chain of ZAX210

• Applicant: Dr.-Ing. Madlen Ullmann
• Subject Area: Primary Shaping and Reshaping Technology, Additive Manufacturing ; Synthesis and Properties of Functional Materials ; Mechanical Properties of Metallic Materials and their Microstructural Origins
• Term: since 2025
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 563064587

The goal of this project is to develop fundamental scientific knowledge about the material behavior of the calcium-containing magnesium alloy ZAX210 during an innovative wire production process. This process combines Twin-Roll Casting (TRC) and Continuous Rotary Extrusion (CRE), aiming to create magnesium wires efficiently and cost-effectively. These advancements are particularly valuable for lightweight applications in transportation, contributing to energy efficiency and sustainability. The focus is on investigating the microstructure and texture evolution during the CRE process. Various process parameters, such as speed, temperature, and the condition of the starting material, will be analyzed to understand their impact on the final properties of the alloy. Special emphasis will be placed on understanding the interactions within the different sub-processes of CRE - such as rolling, shearing, and extrusion - and their collective influence on the material's mechanical performance. Additionally, the project aims to develop a Visco-Plastic Self-Consistent (VPSC) model, which will predict texture and recrystallization during deformation. This simulation tool will be validated using experimental data obtained through detailed material characterization (including optical microscopy, scanning electron microscopy, and EBSD). Another key objective is to optimize heat treatment processes to tailor the material's properties for specific applications. These treatments will be designed to enhance the mechanical performance of the final wire products, making them suitable for further processing or direct industrial use. The project combines experimental research with advanced simulation techniques, fostering a close collaboration between the Institute of Metal Forming (IMF) and the Light Metals Competence Center Ranshofen (LKR). By addressing key research gaps, this project will deepen our understanding of the deformation mechanisms in calcium-containing magnesium alloys, unlocking their full potential for industrial applications.

• DFG Programme: Research Grants
• International Connection: Austria
• Partner Organisation: Fonds zur Förderung der wissenschaftlichen Forschung (FWF)
• Cooperation Partner: Dr. Johannes Kronsteiner