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TECH WATCH Magnesium's Big Break? The Very Active Additive Industry Considering the tools of the century-old auto manufacturing trade, 3D printing has come a very long way in a short time. But there's plenty more growth to come. In fact, the Global Automotive 3D Printing Market 2017-2021 study from HTF Market Research ( htfmarketreport.com ) looks at the competitive landscape in the years to come, and predicts that growth could be as much as 45.5 percent globally by 2021. One interesting finding: some researchers think the process is still in its infancy. Automotive components made out of magnesium account for only about 1 percent, or 33 pounds, of a typical vehicle's weight, according to a report from the Department of Energy (DOE). That's a shame, because magne- sium is 75 percent lighter than steel, 33 percent lighter than aluminum and is the fourth most-prevalent element on earth. Only iron, silicon and oxygen beat it, according to the Pacific Northwest National Laboratory ( pnnl.gov ), part of the DOE. In addition to its volatile pricing, several scientific factors inhibit raw material refiners from flattening magnesium into sheets at low temperatures, including difficulty blending it with other elements to form strong alloys. PNNL, however, reports that it has developed a new process that could make it far easier for the auto industry to utilize the plentiful mineral. The new extrusion approach improves the energy absorption of magne- sium by creating microstructures, which are not possible with traditional extrusion methods. This extrusion method also helps in ductility, or just how much the metal can be stretched without snapping, according to researchers. The PNNL team commissioned a custom- built machine, called Shear Assisted Processing and Extrusion (ShAPE), to test the theory. By spinning magnesium at the same time it's being forced through a tool, researchers say enough friction-based heat is generated to press the material into a die. No additional heating systems are needed to make this happen. "Right now, manufacturers opt for low-cost aluminum in components such as bumper beams and crush tips. Using our process, we have enhanced the mechanical properties of magnesium to the point where it can now be considered instead of aluminum for these applications—without the added cost of rare- earth elements," says principal investigator and mechanical engineer Scott Whalen. In a DOE-funded project, Magna ( magna. com ) is collaborating with PNNL to create and test magnesium parts at one of its facilities near Detroit. Profil ® -FabriSteel TM self-piercing, riveting, and clinching fasteners Assorted threaded studs, nuts and installation systems yield high performance, thin metal panel attachment. ATLAS ® blind threaded rivet nuts Fasteners for thin sheets or tubes where only one side is accessible for installation. PEM ® self-clinching fasteners Available with wide variety of standard and micro fasteners for attachment in thin sheets. Fasteners and precision components… for demanding automotive applications. Mechanically attached fasteners Promotes strength in lightweight designs while providing strong threads in thin materials. Our fasteners eliminate loose hardware and the need for welding. High volume, automatic installation capable. • Global product availability • Complete design engineering services • Full quality (PPAP) documentation • Fully certified ISO/TS/BS OHSAS factories • Complete fastener installation systems • A2LA Accredited Lab 107 ©2017 www.pemnet.com PennAuto TM Threaded fasteners and components Unique manufacturing capability combines complex forged/formed geometries with secondary turning/machining operations at globally competitive pricing. Global Services and Capabilities See our "Automotive Solutions" section at: 12 GEAR GEAR