CLEAN-Mag research project: TAF develops new melt feeding technology for more energy-efficient magnesium processing
Weitere Bilder
TAF Thermische Apparate Freiberg GmbH, a company within the Pörner Group, has successfully completed the three-year CLEAN-Mag research project in collaboration with eleven other industry and academic partners. The TU Bergakademie Freiberg coordinated the project, developing innovative technologies and process chains that will enable the CO₂-neutral and significantly more energy-efficient processing of the light metal magnesium for the transportation sector. Funded by the Federal Ministry for Economic Affairs and Energy (BMWi) as part of the Technology Transfer Programme for Lightweight Construction (TTP Leichtbau), the project was managed by the Project Management Agency Jülich (PTJ).
Lightweight construction is a key technology for decarbonising the transport sector. Lighter components can significantly reduce energy consumption and emissions, particularly in vehicles, rail vehicles, aerospace applications and disaster response equipment. However, processing magnesium into lightweight components has traditionally been associated with high energy consumption. This is precisely where CLEAN-Mag comes in. The project aimed to make processing as CO₂-neutral as possible by using lower temperatures in forming processes, more innovative and energy-efficient methods to shorten process chains, and hydrogen in heating technology.
Magnesium, the lightest engineering metal, offers great potential for sustainable applications when combined with the calcium-containing ZAX210 alloy. Innovative technological approaches such as green heating technologies (hydrogen burners, green electricity), optimized process chains, and reduced forming temperatures enable significant efficiency gains and emission reductions.
TAF as a Key Partner in the 12-Member Consortium: New Melt Feeding System for Optimized Magnesium Processes
TAF contributed significantly to the consortium by developing new melt feeding systems for wire and strip casting at the TU Bergakademie Freiberg Technical Center. The challenge was processing the calcium-containing magnesium alloy ZAX210. Preliminary tests showed that existing metering tube systems led to deposits, blockages, and process instabilities due to the calcium content of the alloy, even after a short period of operation. This was due to the alloy’s pronounced tendency to stick, a property not evident in previously used magnesium materials.
TAF subsequently developed a process-stable feeding technology with an optimized casting nozzle design. Factors such as temperature control, material durability, and ease of maintenance were specifically considered. Extensive finite element (FE) simulations were used to validate the design. Additionally, long-term thermal and melt feeding tests were conducted under real operating conditions.
In addition to developing the melt feeding system, TAF supported the development of technologies for various magnesium semi-finished products. These products include long items, such as wires, rods, and profiles, as well as flat items, such as sheets and strips. Particular emphasis was placed on the innovative GieWaCon process, which combines cast rolling with continuous Conform® extrusion. Due to the direct coupling of these processes, the heat contained in the melt can be utilized much more efficiently, resulting in additional energy savings.
Two process routes were investigated in parallel for the production of flat products:
- Cast rolling followed by strip rolling.
- Strip casting combined with surface and heat treatment.
The project evaluated both processes in terms of energy consumption and emissions to identify the most efficient industrial implementation.
Successful Project Results
The developed solutions were successfully commissioned and tested. The results speak for themselves:
- Stabilization of the test conditions for strip casting
- Successful optimization of the existing strip casting line
- Redesign and commissioning of the melt feed system for wire casting
- Successful test runs of the new headbox and feed systems at the TUBAF pilot plant
Contributing to a Climate-Friendly Circular Economy
The project's results are significant not only for magnesium processing, but also for other applications. The developed technologies can be applied to other light metals, such as aluminum. Magnesium itself offers key advantages for a sustainable industry: It is widely available, fully recyclable, and enables significant weight savings in many applications.
CLEAN-Mag is part of the industry initiative, “NOCARBforging2050,” which pursues the vision of a greenhouse gas-free, circular economy for ultralight components in the transportation sector. With the results achieved, TAF is laying an important technological foundation for the industrial implementation of this goal. The project shows how combining targeted research with engineering and manufacturing expertise can establish a foundation for a climate-friendly circular economy in lightweight construction.
The results of the three-year project were recently presented at the site of project partner Stolfig Leichtbau Kompetenzzentrum GmbH. The project consortium is already working on specific plans for further applications of the technology. For more information about the project and upcoming events, please visit www.clean-mag.de.
Through its contribution to CLEAN-Mag, TAF Thermische Apparate Freiberg GmbH further establishes its position as a leader in innovative pilot and research plants, as well as a development partner for sustainable process technologies within the Pörner Group.
