Solikamsk Magnesium Works (SMW) : Automotive and Motorcycle Wheels

The benefits of magnesium (Mg), and Mg-engineered-alloys come from the materials inherent low density, excellent strength to weight ratio, good fatigue strength, and extraordinary dampening capacity. SMW exploits Mg and its products by utilizing its vast experience as a Mg producer, and furthers the use of Mg by exploiting the material properties beyond current applications by employing advanced forging technologies to produce one-piece forged wheels. A brief background, In 1936 SMW in Russia began the production of Mg ingot, and in 1939 Mg-alloys were being produced as well. By 1958 SMW had optimized the process for production of high purity Mg (99.95%), and in the 60s came the development of more exotic alloys, including the development of Mg-Zr master alloys. Beginning in 1991, SMW started casting wheels for sale domestically and to the Japanese racing community. In 1992 SMW was privatized, and subsequently entered the worlds Mg supply market. In addition to Mg and Mg-alloys, numerous advanced manufacturing processes have resulted from years of research and development in Russia funded by the aviation and defense industries. They led to the production of various wrought magnesium products, including one-piece forged wheels. To date, the production of Mg components has been primarily accomplished by means of casting technologies (i.e. gravity, pressure, and thixotropic). The casting process generally has some inherent disadvantages, including differing local solidification structures, void / porosity content, and shrinkage cavities. As part of its wheel casting experience, SMW has developed some important expertise -- including ability to decrease the grain size and to significantly reduce the content of Fe and Ni in the alloy. These developments contribute to lowering the rate of corrosion. Forming of Mg, including forging, generally offers extreme challenges due to its hexagonal closely-packed crystal structure which has limited slip planes. Elevated temperature will activate additional (pyramidal) slip planes; however, overall formability is found to be difficult due to the materials strain rate sensitivity, which makes for an extremely cumbersome (expensive) production process. Forged and extruded magnesium products (wrought products) will play a key role in the automotive industry as consorted efforts are put forth to lighten, and thus, produce more fuel-efficient automobiles. The weight reduction for wheels is most efficient because of the rotational mass consideration. In other words, every one (1) pound of un-sprung weight that is eliminated has the equivalent, or exceeds five (5) pounds of sprung weight on the chassis, thus, yielding an effective 1 to 5 weight savings ratio. Because of the limited knowledge and development in the area of forged Mg wheels, there are few suppliers of this product. O.Z. Racing Wheels and B.B.S. offer forged and spun Mg wheels for Formula1, C.A.R.T, and I.R.L racing applications. All Formula-1, and approximately 40% of C.A.R.T. and I.R.L. race cars use forged and spun Mg wheels, with the remainder utilizing cast Mg wheels. With its advanced forging technique and

capabilities, it is economically feasible for SMW to offer one-piece forged Mg wheels for OEM and aftermarket applications. For motorcycles, SMW currently supplies forged wheel blanks that are final-machined and distributed by Marchesini division of Brembo for the AMA Superbike Racing League, as well as for the aftermarket.

The Technical Aspects, Challenges, and Production issues to be discussed will be:

1) SMW / Magnesium Background Marketing

2) Forging Vs. Casting Alloy Selection Grain Structure Process Advantages

3) Corrosion Considerations Minimal Ni & Fe Coating processes

Solikamsk Magnesium Works (SMW) : Automotive and Motorcycle Wheels

Picture 1, cast-mg-auto : Magnesium Cast Automotive Wheel

Solikamsk Magnesium Works (SMW) : Automotive and Motorcycle Wheels

Picture 2, forged-mg-auto : Magnesium Forged Automotive Wheel

Solikamsk Magnesium Works (SMW) : Automotive and Motorcycle Wheels

Picture 3, forged-mg-motorcycle :Magnesium Forged Motorcycle Wheel

SOLIKAMSK MAGNESIUM WORKS (SMW) - Russia

Magnesium wheels * Forged One-Piece * Cast

1936 - Began Mg production 1958 - Optimized process for 99.95% pure Mg 1960s Developed Mg-Zr master alloys 1991 Wheel casting 1992 - Privatization

Vertically Integrated Mg Producer Smelt Cast (sand, gravity, dc) Extrusion Technology Forging Technology

Engineered Magnesium Alloy Advantages

Low density (2/3 the weight of Al) Strength / Weight ratio Good fatigue strength Excellent dampening capacity

Automotive Motorcycle Gravity cast Sold in E. Europe / Japan

Cast Mg Alloy
ML 15 : Mg-Al-Zn-Mn-Si Similar to AZ91C-F Low Fe and Ni
Decrease in corrosion potential

Cast Alloy - Corrosion Reduction

Critical Fe/Mn ratio not to exceed 0.032 Low Ni Low Fe

ALLOY

Fe Content (PPM)

Corrosion Rate (mm / yr)

AZ91-C

350

0.0043

AZ91-C

10

0.0027

Automotive (13 to 20 diameter) Motorcycle (Marchesini)

Forging Alloy
MA2 : Mg-Al-Zn alloy

Other Mg-Al-Zn alloys

AZ21 AZ31 AZ61 AZ80 Great Britain Mag-S-111

Alloy MA2-F AZ80-F ZK60-F Al6061T6 AZ91CT6

UTS (MPA) 290 330 340 310 275

YS-t (MPA) 270 230 260 276 145

YS-c (MPA) 190 170 230 241 145

Elong. (%) 12 11 11 12 6

Process Advantages
100% forged structure
Preferential grain flow 3-dimensional strength regime

No secondary spinning operation No modular design (as in 2 & 3 piece)

Cast products
Sand Die Thixotropic

Wrought Products
Extrusions Forgings

INFORMATION / CONTACT

MAGNESIUM.COM MAGNESIUMWHEELS.COM
Steven Barela
sb@magnesium.com