76th Annual IMA World Magnesium Conference 2019



Schedule is subject to change.

Tuesday, 14 May

09:00 –14:00

Executive Committee Meeting (closed)


Wednesday, 15 May

09:00 – 14:00

Board of Directors Meeting (closed)


09:00 – 18:00

Registration Open


15:00 – 16:30

European Committee Meeting (concurrent)


15:00 – 16:30

Americas Committee Meeting (concurrent)


16:00 – 18:00

Exhibitor Set Up


18:30 – 21:30

President’s Reception


Thursday, 16 May

07:00 – 08:30

Continental Breakfast


08:00 – 17:00

Registration


08:00 – 17:00

Exhibit Hall Open


08:30 – 10:05

Session 1

Welcome & Opening Remarks
by IMA President Todd Olson

Program Overview
by Alan Luo, Conference Chair

KEYNOTE: Global Primary Magnesium Supply and Demand
by Martin Tauber, FAURIS Management

Session and speaker information coming soon.


KEYNOTE: Current Status and Future of International Standards for Magnesium Alloys
by Fusheng Pan, National Engineering Research Center

Session and speaker information coming soon.


Standards, Regulations, and Materials of Mg Application in Rolling Stocks: CR400 as An Example
by Gaofeng Quan, Litmat Technology

China high-speed train modeled CR400 series are the highest speed railway passenger train in the world for actually running rolling stocks. High strength Mg components are being used for lightweight manufacture in the inner components. The high strength Mg alloy diecastings, extruded profiles are being used in seat framework, luggage rack, floor side frame, side wall profile and so on. These applications make their headway not only through materials, processing, protection, but also by large amount of convoying work: general assessment of performance, long term reliability, manufacturing and installment cost, and fire prevention , maintenance standard and regulation as well. By the exhibition of those samples, in this presentation, the fire prevention , maintenance standard and regulation for CF400 high speed train’s Mg alloy component will be analyzed.



10:05 – 10:30

Morning Break - Exhibitions & Posters Open


10:00 – 16:00

Spouse/Guest Tour - Meet in Kempinski Hotel Main Lobby (registered Spouse/Guest only - additional fee required)


10:30 – 11:20

Session 2: Automotive Applications
Session Chair - Fernando Franca

Strategy for Next Generation Car's Function Integrated and Lightweight Designs
by Horst Friedrich, German Aerospace Center

New vehicle concepts with electric drivetrains or autonomous drive for people movers, passenger or goods cars will change the paradigms of mobility. Still remain energy efficiency, safety and economic attractively of paramount interest. With respect to this, weight is a must and Magnesium solutions could show even more potentials: casted structures with integrated functions, peeling mode mechanisms or foam filled profiles are examples developed and demonstrated in DLR's meta project for Next Generation Car (NGC). Mg extrusions with polyurethane core show up excellent energy absorption compared to hollow steel. Light and cost attractive Mg structures are shown with integrated A-pillar demonstrators, bringing together many single parts within one big casting that provides the advantage of 50% weight reduction. Challenges like modularisation and electrification strategies have to be met, an example is a highly integrated battery trough. Further research and development activities focus on hybrid design, e. g. the combination of castings with additive manufacturing and the use of process digitalization. For greenhouse gas emissions over the whole life cycle our comparison gives evidence that different Mg production routes determine the final result and that modern electrolysis processes or biomass based energy in production is advantageous even compared to an aluminium reference. The integrated approach of combining development and optimization methods and tools for the design is the key for developing concepts for holistic lightweight solutions and new vehicle concepts utilizing highly automated and autonomous driving abilities.

Prof. Horst Friedrich studied engineering at the Technical University of Munich. In 1996, Prof. Friedrich joined Volkswagen AG in Wolfsburg as head of vehicle research, where at least he was Directore of Group research for materials technology and vehicle concepts. Since 2004 he is Director of the Institute of Vehicle Concepts of the German Aerospace Center (DLR) in Stuttgart. The institute develops concepts of road and rail vehicles for next generations. The research fields are Alternative Power Trains and Energy Conversion as well as Light Weight Design and Hybrid Construction methods. At the same time he became professor for vehicle concepts at the University of Stuttgart and he is lecturer at the Technical University of Berlin. He is editor of several books and performed over 500 publications. He is organising DLR’s MaterialAutomotiveSymposia for 9 years in Stuttgart including Magnesium Sessions.


Towards Processable and Economic Magnesium Sheet Components in the Automotive Industry
by David Klaumuenzer, Volkswagen AG

Session and speaker information coming soon.



11:20 – 11:30

Automotive Award Announcement


11:30 – 11:40

Environmental Responsibility Award Announcement


11:45 – 12:15

IMA Member Meeting


12:15 – 14:00

Lunch


14:00 – 15:15

Session 3: Chinese Language Session
Session Chair - Zisheng Zhan

Development Report of China Magnesium Industry in 2018
by Ruhai Lin, China Magnesium Association

Session and speaker information coming soon.


Update on Qinghai Salt Lake Magnesium Plant - Process Optimization and Production Ramping Up
by Xingfu Wang and Guojian Liu, Qing Hai Salt Lake Industry Co.

This presentation will update the current operation status of the Qinghai Salt Lake Magnesium plant. While all production equipments of the 100kmt Magnesium facility have been ready for mass production, 5 dehydration lines and 26 electrolysis cells are now in mass production. The dehydrated MgCl2 prills meets the designed specification and the pure Mg produced has an impurity of over 99.95%. Some technical improvements and optimizations on the processes and equipments have been achieved in the past year.


The Recent Progress of China's Magnesium Industry and Market Under the Background of Economic Transition
by Chunming Dong, Sunlight Metal Consulting

The presentation will cover the following topics. 1. Supply and market balance of China Magnesium. This part relates to magnesium market , including production, consumption, export trade, price change and consumption structure, and, meanwhile, analyzes briefly the factors influencing these indicators,,this part also discuss the problems and challenges facing China’s magnesium industry. 2. Improvement of primary magnesium enterprises under the situation of new environment protection. This part describes the progress made by magnesium enterprises in environmental improvement, the work to be done in the future, and the impact on market supply and competition.3. Development and application of magnesium products in China. Through several cases, this part introduces the new achievements in market development. 4. China's magnesium industry and market outlook. Taking a longer term perspective and considering economic policies, market demand, material competition, technological progress and other factors, this part analyzes the market prospect of magnesium and the opportunities for China's magnesium industry.



15:15 – 15:45

Afternoon Break - Exhibition


15:45 – 17:00

General Sessions 4: Post-processing Technologies
Session Chair - David Wanless

Magnesium Corrosion and Coating Solutions for Consumer Electronics Enclosures
by Han Li, Microsoft

The paper reviews the most popular magnesium pretreatment and finish options for the enclosures of consumer electronics.

Chemical Pretreatment + Organic Paint

  • Passivation + Organic Paint
  • Siloxane + Organic Paint
  • Organic-inorganic Hybrid Sol-gel + Organic Paint

Electrochemical Pretreatment + Organic Paint

  • Electroplating (Cu-Ni-Cr) + Organic Paint
  • Micro Arc Oxidation (MAO)/Plasma Electrolyte Oxidation (PEO) + Organic Paint

Non-paint Finish

  • Electroplating
  • Organic-Inorganic Hybrid Sol-gel
  • MAO/PEO (Black)

Aluminum Modification - Anodization

  • Al Modification by Sputtering PVD - Anodization
  • Al Ion Vapor Deposition - Anodization
  • Al Electroplating in Organic Solvent - Anodization
  • Al Thermal Spray - Anodization
  • Al Cold Spray or Kinetic Metallization - Anodization

Han Li is a Senior Materials Engineer working at Microsoft’s hardware engineering group. Han is experienced in developing advanced materials and finish technologies for consumer electronic products. Han was worked on the materials and finishing of Surface Pro 3 and Surface Book in the last couple of years. Magnesium alloys were used to make the enclosures of both products. Han owns a Master of Science in Polymer Chemistry and Physics and an MBA.


Hybrid Joining Processes and Surface Protection of Magnesium (HybOM)
by Christoph Schendera, Europaeische Forschungsgemeinschaft

ZIM Cooperation Network "Hybrid Joining Processes and Surface Protection of Magnesium" ("HybOM"). The goal of the ZIM network "HybOM" is the development of magnesium-specific manufacturing processes and procedures in order to establish the use of magnesium in the areas of vehicle, aircraft and mechanical engineering outside the premium markets. In order to create the technical prerequisites for this, the Network considers magnesium along the entire process chain from component manufacture through forming, joining, surface treatment, quality control, ... "HybOM" also links togehter research institutions, OEMs, semi-finished product and adhesive manufacturers as well as end users and closes the knowledge gaps for the continuous description of the process chain according to DIN 8580: - Forming => Hybrid joining => Surface treatment => Quality control. The work is illustrated by the example of the linkage of the process steps (1) die casting, (2) coating and (3) hybrid joining of components. It predicts the local distribution of the release agent in the component by using numerical analysis and identifies the geometry-dependent / mould fill-related release agent accumulations and allows the identification of possible coating errors or disruptions of the bonding process.


Wire-based Additive Manufacturing of Mg Alloys
by Simon Frank, LKR Leichtmetallkompetenzzentrum Ranshofen GmbH

Magnesium based materials offer a very low density compared to its contenders aluminium and steel. They also show high specific strength, making it the preferred material for future light weight design components. The additive production of individualized and complex components is increasingly attracting the interest of potential users such like aerospace automotive and biomedical areas. The wire based arc additive manufacturing (WAAM) as an environmentally friendly and material-efficient is becoming a powerful alternative technology to the more well-known powder-based processes. The magnesium wire developed in this study made it possible to manufacture magnesium alloy components using the WAAM process. The process reliability was also increased compared to existing AZ wires. Tensile tests and microstructure analyses were carried out as characterization methods. It could be proven that the manufactured object has very isotropic properties both in terms of strength and elongation compared to the observed standard value.

Simon Frank received a diploma degree in materials and process engineering from the University of Applied Sciences Upper Austria in 2015. After finishing the University, Mr. Frank joined the LKR-Ranshofen as a Scientist in the department of casting technology in the field of high performance light metal alloy development and process optimization. In 2017 Mr. Frank finished an additional education as “IWE” in the field of joining technology specialized in welding technology (IWE-International Welding Engineer). Since then he is supporting the group for welding and AM-Technology in development of special alloys for small-batch-wire manufacture. He is experienced in light metal casting technology, magnesium alloy development and the processing of magnesium alloys.



17:00 – 17:10

Process Award Announcement


18:00 – 21:00

IMA Members' Only Reception
Budapest History Museum


Friday, 17 May

07:00 – 08:30

Continental Breakfast


08:00 – 17:00

Registration


08:00 – 16:30

Exhibit Hall Open


08:30 – 9:45

Session 5: Overviews
Session Chair - Todd Olson

KEYNOTE: 40 Years of Magnesium Research - Assessment of Contribution to the Progress in Magnesium Technology
by Karl Ulrich Kainer, Helmholtz-Zentrum Geesthacht

Since the end of the last millennium, Mg alloys have made inroads into the applications in automotive industries as well as in consumer, computer and communication (3C) applications. Their favourable property profiles high specific strength, good machinability, recyclability etc. promote increased usage. Still, the full potential of Mg as a structural material has not been achieved. Despite magnesium alloys being in service for almost one hundred years, there is still a lack of knowledge potential of Mg alloys compared with other metallic materials such as steel or aluminium: Design, processing, potential etc.. New alloys and new or optimised processes are also creating new ideas and stimulating competition for advanced developments to substitute traditional materials. However, the implementation of new alloys and advanced processes has always to face hurdles and hindrances. New fields of application like degradable implants or anodes for batteries require tailored microstructure design and functionalisation of surface for complex environments and functionalities. The presentation will give an overview on the status of the development for a selection of application field and discuss success, potentials and problems with the implementation into the market.


Research and Development Status of Magnesium Alloys in Korea
by Kwang Seon Shin, Korea Magenesium Technology Reasearch Association

Magnesium alloys are the lightest structural metals, and have good physical and mechanical properties that make them extremely attractive for applications requiring lightweight materials. The global market for magnesium alloys has steadily expanded in the past decade, stimulated by the strong demand from the automobile and electronic industries for lightweight magnesium components. In order to meet the demand of new high performance alloys and overcome technical challenges, there has been active research at universities, national research institutes and industries to develop new magnesium alloys and processing technologies including twin-roll casting process and additive manufacturing in Korea. This lecture will introduce the major magnesium R&D activities and recent research highlights in Korea.

Dr. Kwang Seon Shin has been professor of the Department of Materials Science and Engineering at Seoul National University since 1991. He launched research program on magnesium alloys and Magnesium Technology Innovation Center at SNU, He is former president of the Korean Institute of Metals and Materials at which he started the Magnesium Committee and co-founded its English journal, Metals and Materials International. He is a member of the National Academy of Engineering of Korea and the Chairman of the Korea Magnesium Technology Research Association. His research focuses on the development, processing, and characterization of advanced structural materials, including magnesium, aluminum, and copper alloys, particularly the development of advanced processing technologies and high-performance magnesium alloys with high strength, ductility, formability, and corrosion resistance.


Current Status of Magnesium Industries and Progresses of Applications in Japan
by Kazumasa Yamazaki, Nippon Kinzoku Co.,Ltd.

Activities of JMA, current status of magnesium industries and progresses of applications in Japan are reported. JMA continues to hold many seminars as usual year to enhance its activities. As committees, we began supporting the development of batteries besides the development of high-speed railway vehicle and application to automobiles. Especially there were big progresses in the field of batteries. Regarding primary batteries, in recent years, natural disasters such as large typhoons and earthquakes occurred frequently in Japan, so their importance increased and the installation of high capacity batteries increased. As for secondary batteries, although it is still in the research stage, there has been a great progress in the development. This is that the optimum magnesium alloy candidate as a negative electrode material was found.

Mr. Kazumasa Yamazaki received a Master of Mechanical Engineering in 1976 from Waseda University and in 2000 received his Doctorate in Engineering from Kyoto University. In his early career, Mr. Yamazaki worked at Nippon Steel, until 1981 when he joined Max-Planck Institut Feur Eisenforschung. After three years at Max-Planck, Kazumasa returned to Nippon Steel. In 2005, Kazumasa joined Nippon Kizoku, where he currently works.



9:45 – 9:55

Commercial Award Announcement


9:55 – 10:30

Morning Break - Exhibition Open


10:30 – 12:10

Session 6: New Processes/Applications
Session Chair - Martin Tauber

Advances in Novel, Zero Waste, Modular Magnesium Metal Process
by Gillian Holcroft, Mag One Products, Inc.

Serpentinite tailings from abandoned mining operations in Quebec, Canada contain approximately 23% magnesium, 18% silica, 6% iron and 0.2% nickel. Mag One has demonstrated on a pilot scale that this carbon-free feedstock can be transformed into high purity magnesium oxide, a high-value amorphous silica and an iron / nickel by-product suitable for nickel smelters. By transforming essentially 100% of the tailings into commercially valuable products, the resulting patent-pending process generates close to zero waste. The fine-grain MgO produced from tailings enables Mag One to pursue its novel approach to producing primary magnesium metal through aluminothermic reduction. The modular process produces magnesium plus salable by-products that significantly offsets operating costs, a key strategy for the company to become the lowest cost, lowest carbon-footprint producer of Mg metal. This paper will present findings from both the pilot plant and from the Mg metal bench-scale work, including a review of by-product qualifications.

Gillian Holcroft obtained both her Bachelor and Master's degrees in Chemical Engineering from McGill University. Gillian began her career at the Noranda Technology Center where she transitioned from technology development and techno-economic modeling to operations support at Canadian Electrolytic Zinc and commissioning support of Magnola Metallurgy's 63,000 TPY Mg metal operation. Over Gillian's 30-year career she has been involved in Advanced Technology, Environmental Services, Mining & Metallurgy, US Department of Defense as well as International Trade. Her expertise has focused on commercializing environmentally sustainable processes. Gillian is currently President of Mag One Products, a publicly listed company.


Modeling Directly and Indirectly Heated Furnaces for Mg Production by Carbothermal Reduction
by Boris Chubukov, University of Colorado at Boulder

Magnesium production by carbothermal reduction represents an attractive but elusive method of primary production. Here we present a 2D model of a furnace for magnesium oxide carbothermal reduction including transport phenomena and reaction kinetics. The model was validated in an indirectly heated furnace at production rates of 150 g/h Mg and expanded to predict the behavior of larger indirectly and directly heated furnaces. In an indirectly heated furnace, even thin reaction tubes (<5 cm) result in significant heat transfer limitations, in that the center of the tube remains >50°C cooler than the furnace. The reaction becomes completely heat transfer limited for tubes of >10 cm diameter. For a directly heated furnace (electric arc), the reaction is limited by mass transfer resulting in the bed heating up to >2000°C in order to sustain the production rate

Boris Chubukov recently finished his PhD at the University of Colorado at Boulder where he researched the fundamental aspects surrounding magnesium metal production by carbothermal reduction. The promising results from his team’s bench-scale experiments led to the formation of Big Blue Technologies and the development of a proof-of-concept system to produce magnesium. Currently, Boris is leading the development of a 50x scale-up system to produce magnesium metal by carbothermal reduction.


Development of Magnesium Alloy Tube and Development of Bioabsorbable Scaffold for Coronary Artery
by Hironori Ueda

In this presentation we will present the development situation of the magnesium alloy tube and the bioabsorbable scaffold for coronary artery using it. We established plastic processing technology for precision, thin walled and thin diameter magnesium alloy pipe which was considered difficult. Since this pipe does not have seams, it is suitable for medical devices such as scaffolds which are subjected to large deformation and exposed to a severe corrosive environment. We have also developed not only plastic processing technology but also alloy composition, casting technology, laser processing technology, surface treatment technology, and by combining these techniques, we made a pipe for bioabsorbable scaffold for coronary artery It became possible to do. Currently, with the aim of putting bioabsorbable scaffold for coronary artery into practical use, we are developing with Japan Medical Device Technology Co., Ltd.

Mr. Hironori Ueda began his career as an Engineer of Factory Production Technology for Coli Coating Line in Nippon Steel Corporation in the early 90s. He then became a Researcher of Steel at Nippon Steel from 1994 to 2011. He received his PhD of Engineering in 2002 from Chiba University. He currently works as the Chief Researcher of Steel at Nippon Steel and Sumitomo Metal.


Development of Magnesium Based Materials With Ignition Temperature Beyond 1000 C
by Manoj Gupta, National University of Singapore

Magnesium is fast emerging as most potential lightweight material in engineering applications (automobile, aerospace, sports, space and electronics) primarily due to its capability to reduce human and environmental stress (land, water, air and electromagnetic). Common perception still prevailing in scientific community is that magnesium can be easily ignited and hence this presentation will aim to debunk this myth and provide insight into the ignition capability of magnesium placing special emphasis on recent developments where the ignition temperature of magnesium based alloys is taken beyond 1000 C close to its boiling point.



12:10 – 13:30

Lunch - Exhibition Open


13:30 – 14:45

Session 7: Wrought Processes
Session Chair - Karl Kainer

Recent Developments of Magnesium Sheet Alloys for Automotive Applications
Alan Luo, Ohio State University

Magnesium (Mg) sheet alloys have been attractive to the automotive industry for structural and panel applications. Major challenges for automotive applications of Mg sheet alloys include formability, corrosion, joining and costs (in material and manufacturing). This talk provides an overview of low-cost Mg sheet alloy developments in the last decade. Examples are given on how to integrate experimental, computational and data tools in the development new Mg sheet alloys.


Ultra-strong and Ductile Wrought Mg-Gd-Y-Zn-Zr Alloys and Their Applications
by Mingyi Zheng, Harbin Institute of Technology

Ultrahigh strength Mg-Gd-Y-Zn-Zr alloys with different RE content were processed by direct-chill casting, hot deformation (extrusion, rolling and forging) and ageing treatment. The alloy ingots with diameter up to 520mm and length up to 3000mm were fabricated by vertical direct-chill casting. The homogenized billet was processed by conventional extrusion, rolling and forging. Then the deformed alloys were subjected to T5 ageing treatment. The extruded Mg-8Gd-4Y-1 Zn-0.4Zr alloy after T5 treatment exhibits a tensile yield strength, an ultimate tensile strength and an elongation to failure of 466 MPa, 512 MPa and 14.5%, respectively. The superior strength and ductility of the deformed alloy after T5 treatment was mainly attributed to the bimodal microstructure and the closed volume formed by the precipitation of dense nanoscale basal and prismatic precipitates. The alloys exhibits excellent formability, the extrusion rods, plates, tubes and profiles and complex forging components were fabricated for aerospace and space applications.


Thermomechanical Processing of High Strength Rare Earth Magnesium Alloys
by JiaHua Miao and Chunjiang Ma, Allite Inc.

Aiming at improving mechanical properties, plasticity and deformation processing of conventional magnesium alloys, ALLITE.inc has developed two unique rare earth magnesium alloys with high strength, high plasticity and good corrosion resistance. The relationship between the proprietary composition, cooling and extrusion processing technology and microstructure and mechanical properties of these two alloys AE81 and ZE62 is discussed in detail in this paper. Allite Super Magnesium AE81 is designed specifically for application where weldability is a priority in combination with excellent strength and good elongation. SuperMag ZE62 is designed to deliver a superior combination of tensile strength of 380 MPa, yield strength of 320 MPa and elongation of more than 15%. ZE62 is a high-performance alloy that enables shapes and structures never before possible, primarily through forging processes. The Allite.inc magnesium alloys are specifically designed to be widely used in performance sports equipment, rail transit, automobile and aerospace industry.



14:45 – 14:55

Wrought Award Announcement


14:55 – 15:30

Break - Exhibition Open


15:30 – 16:20

Session 8: Casting Processes
Session Chair - Richard Berkmortel

Developing High Performance Die Casting Magnesium Alloy Using Light Rare Earth
by Xiaoqin Zeng, Shanghai Jiao Tong University

Xiaoqin Zeng, PhD, Professor, doctoral supervisor. Vice dean of School of materials science and engineering, Shanghai Jiao Tong University, winner of National Outstanding Youth Science Foundation of NSFC. He chaired and participated in more than 30 national key R&D projects, 863 projects, 973 projects, National Natural Science Foundation of China, major basic research projects in Shanghai, international cooperation of the Ministry of Science and Technology. He has carried out research on high temperature oxidation mechanism of magnesium, strengthening theory of rare earth magnesium alloys, hydrogen storage magnesium alloys and magnesium battery materials. Over seventy patents of authorized invention have been granted, He also received several awards, including the second prize of national science and technology progress, the second prize of national defense science and technology, the second prize of technological invention of the Ministry of Education, the first prize of Shanghai technological invention and the second prize of Shanghai technological progress. In 2011, he received the magnesium research award awarded by Helmholtz-Zentrum Geesthacht, the famous international Magnesium Research Institute.


Influence of Carbon Addition on Mechanical Properties of Various Magnesium Alloys Formed by Thixomolding
by Makoto Hino, Hiroshima Institute of Technology

The effects of carbon nanoparticles fixed to the AZ91D and AM60B magnesium alloy chips surface on mechanical properties were examined. The manufacture of magnesium- carbon alloy is not easy, because carbon does not have the wettability for magnesium. However, the magnesium alloy chips fixed carbon nanoparticles make it possible to produce the magnesium-carbon alloy by thixomolding process. The mechanical properties such as the tensile strength and the fatigue strength were improved by only 0.1 mass% of the carbon addition because of the decrease in the void as well as the refinement of crystal grains, and then the AZ91D magnesium alloy was more effective than the AM60B magnesium alloy. Therefore the effect of the carbon addition on the mechanical properties was dependent on the aluminum content in magnesium alloy.

Makoto Hino is a professor at Hiroshima Institute of Technology and specializes ion the field of material science engineering.



16:30 – 18:00

Exhibitor Pack-up


17:30 – 18:30

Closing Reception


18:30 – 19:00

Awards & Recognition Presentation


19:00 – 21:00

Closing Banquet