Enhanced Strength and Corrosion Resistance in Mg Alloys via Dense Ultrafine Twins and G.P. Zones

Objective

Magnesium (Mg) alloys, known for their lightweight and high specific strength, are critical to the EU’s Green Deal and Critical Raw Materials Act—yet their broader use in transport and industry is limited by low strength and poor corrosion resistance. The microstructure of conventional Mg alloys typically fails to balance these critical properties, creating a long-standing trade-off. The CycMag project aims to solve this by engineering a novel microstructure: ultrafine twin boundaries (replacing most non-equilibrium grain boundaries) and nanoscale Guinier-Preston (G.P.) zones (replacing most intermetallic precipitates). This innovative approach promises simultaneous improvements in strength and corrosion resistance, addressing the barriers to wider Mg alloy adoption. To achieve this, the project focuses on developing dilute Mg-Al-Ca and Mg-Zn-Ca alloys, leveraging their potential under specific processing conditions. The core method is multi-directional cyclic compression, a cutting-edge technique designed to induce the targeted microstructure. It integrates materials science, mechanical engineering, and electrochemistry: experiments cover alloy design, casting, and thermo-mechanical processing (with a secondment at CENIM to optimize extrusion/rolling), while advanced characterization tools—including 3D microscopy, in-situ SEM mechanical tests (EBSD/HR-DIC), and advanced electrochemical tests—will map microstructure evolution, validate twin/G.P. zone formation, and establish the processing-structure-properties links. Beyond advancing Mg alloy technology, findings could inform the design of other high-strength, corrosion-resistant alloys. Combining the researcher’s expertise with the support of a leading Mg alloy research group (in IMDEA), the project is well-positioned to achieve its ambitious objectives, thereby strengthening the researcher’s expertise in advanced processing and characterization, laying a solid foundation for an independent research career.