Development of a New Magnesium Alloy with Improved Ductility to Enable Joining via Self-Piercing Riveting (SPR)

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Meridian Lightweight Technologies (MLT) is the largest supplier of lightweight magnesium (Mg) die castingsin the world, serving most of the global automotive manufacturers on three continents. To develop a new Mgapplication, the organization urgently needs a new Mg alloy which can be fastened by Self-Piercing Riveting(SPR) technology. SPR, successfully used to join other metals in automotive components, shows lack ofsuccess and cracking when Mg is in the lower layer of fastening components. MLT, in their internalinvestigations has shown that different Mg alloys have different degree of cracking in the SPR process andbelieves a properly designed Mg alloy could completely eliminate the cracking issue. The new Mg alloy shouldhave good SPR response and offer mechanical, corrosion, casting performance, recyclability and cost similar tothe AM50A Mg alloy. The knowledge generated in this project will give the industrial partner a competitiveedge to develop new business, to innovate, and to secure higher market share. HQP trained in this project willhave key expertise in the lightweight transport applications. They will be positioned to advance the Mgtransformation industry and have transferable skills in electron microscopy, XRD, mechanical testing andcomputational materials engineering. The lightweighting using Mg will have key environmental benefits. CO2emissions from the transportation sector currently contribute 25% of Canada's total greenhouse gas emissions(GHGs) and the government has a target for reducing GHGs by 45-65% by 2050. 10% saving in vehicle weightleads to 6-8% fuel economy, which translates (during the life time of a car) to 17-20 kg reduced emissions ofCO2, per kg of vehicle weight reduced. Another key benefit is value creation in Canada. The automotivesector contributes 12% of Canada's manufacturing Gross Domestic Product (GDP) with more than 550,000jobs. Creating expertise and a technology-base in the Mg automotive parts industry is very important forCanada's global competition, both to sustain the current level and to enable future technologies of electric, fuelcell, and hybrid powered vehicles creating opportunities for new job creation, and environmental sustainability.