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RPI Masters Project Preliminary Final Report Siobhan Fleming 7/25/12 Evaluation of Coating Methods for Corrosion Protection of Magnesium Castings

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Agenda Project Review Research Review Magnesium Magnesium Alloys Magnesium Coatings Recommendations for alloys and coatings

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Project Review Extensive review of technical journals completed Magnesium Alloys Coating for corrosion protection Review highlighted new technology in coatings that may be very successful in corrosion protection with more research. Good alloys for certain application were identified throughout the document and segregated in a final table.

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Research Review Technical journals reviewed through electronic village Offered excellent details for specific uses Provided insight into new technologies Specific texts reviewed for background on magnesium, magnesium alloys and coatings for corrosion protection

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Magnesium Lightest of light metal alloys Low Density Good Heat Dissipation Good Damping Good Electro-magnetic shield Useful in applications were weight is a critical design element Susceptible to corrosion

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Magnesium Alloys Alloys designed to improve corrosion resistance Specific elements offer different benefits when combined into alloy form Benefits are laid out in table format by element in the paper Each alloy has its own benefits Selected alloys are documented in paper for benefits

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Magnesium Coatings Numerous different coatings provide coating protection Example of coating protection for aerospace applications is provided in paper Cold spray appears to be the future of coatings More research is required on specific alloys in order to eliminate the concern of galvanic corrosion.

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Recommendations for Alloys and Coatings. AlloyApplicationNotes AZ91 Cast Helicopter Transmission Housings Less costly, good tensile strength, very susceptible to creep above 120C. Good corrosion resistance. AM60/AM50/AM20 Automotive (wheels, seat frames, steering wheels) Greater ductility and fracture toughness. AS41 Automotive (crank case, transmission housing) Easier than AS21 to cast with better fluidity QE22Aerospace (landing wheels, gearbox housings, helicopter rotor fittings) Superior tensile properties, Expensive due to silver