Researchers from Freiberg and their ten industrial partners are creating novel procedures for the greenhouse gas-free manufacture of lightweight magnesium components as part of the new “CLEAN-Mag” research project.

The group is investigating energy-intensive green processes that might be applied to the magnesium smelting process as a first step. Hydrogen will be used as an alternative fuel because it is climate neutral. Under Prof. Krause’s guidance, the Institute for Heat Engineering and Thermodynamics is developing suitable hydrogen burners as well as firing and preheating systems for this purpose. The researchers are also looking into ways to enhance heat transfer from the heat source to the light metal and finally to the melt.

Additionally, strategies are being developed to improve the utilization of fusion heat in subsequent operations. The team offers the resource-effective casting-rolling technique as a solution, which can generate a semi-finished product from liquid magnesium more quickly than with traditional methods. In order to utilise as much thermal energy from the casting heat on the route to the semi-finished product as possible, various shaping phases must be more tightly linked to the casting-rolling process.

The use of a highly flexible magnesium alloy, which can be shaped into the necessary shape at low temperatures and hence with less energy needed, is a third component of the novel production process. The magnesium alloy ZAX210, which contains calcium, is being studied by the researchers.

The collaborative project’s outcomes are intended to provide a variety of prototype parts, which will later be assessed for their suitability for usage in the mobility industry. The study’s findings are also transferable to different materials and shaping techniques. By doing this, Verbund is working toward its goal of lightweight, climate-neutral building.