Direct Chill Cast Elektron21 [ASTM EV31A-T6] Billet for Machined-from-Solid Aerospace Applications

Magnesium Elektron has developed a process to produce aerospace quality Elektron21 [ASTM EV31A-T6] magnesium alloy in large Direct Chill (DC) cast sections which meet the property requirements of the AMS 4429 sand casting specification for the alloy.  Considerable testing has been completed on both round DC cast billets [10” diameter by 175” long] and slab sections [12.5” x 34.5” x 175”].  Working with Boeing and other aerospace companies, more than three hundred billet sections have been thoroughly examined using both ultrasonic and radiographic techniques, with all solid pieces meeting the radiographic Grade B or better requirements for magnesium castings as called out in Table 7 of AMS 2175.

Following a rigorous qualification testing program, components have now been precision machined from solid DC cast pieces, coated and assembled for use in helicopter applications.  The presentation will review the advantages and disadvantages of machined-from-solid versus sand casting for simple or thin walled components.