The Need

Magnesium is the lightest structural metal and offers compelling weight‑reduction potential for transportation and other markets. However, broader adoption has been limited by the poor room‑temperature formability, modest strength, and narrow processing windows of conventional magnesium extrusion alloys. In particular, existing alloys often exhibit incipient melting and cracking at commercially relevant extrusion speeds, constraining productivity and cost competitiveness for high‑volume applications such as automotive structural components.

The Technology

OSU engineers have developed a family of novel magnesium alloys engineered to enable high‑speed extrusion while delivering an improved balance of strength, ductility, and room‑temperature formability. Through targeted microalloying and control of phase stability, these alloys suppress low‑melting intermetallic phases that typically limit extrusion speed. The result is magnesium extrusions that can be processed at significantly higher ram speeds without incipient melting, while maintaining attractive mechanical performance suitable for downstream forming and structural use.

Commercial Applications

• Automotive extrusions
• Aerospace and mobility platforms
• Consumer electronics housings and frames
• Industrial extrusions requiring high productivity and post‑extrusion forming

Benefits/Advantages

• Higher extrusion productivity
• Improved formability
• Lightweight performance
• Competitive mechanical properties