Magnesium Alloys: Trends, Applications, and New Technologies

Magnesium Alloys: Trends, Applications,

and New Technologies
By Ibtisam Abbasi Jan 15 2003
Reviewed by Lexie Corner

Magnesium (Mg) is renowned for being a lightweight metal that is extensively used in
various engineering applications. It constitutes about 2.7 % of the Earth’s crust,
making it the eighth most abundant material globally.

Image Credit: Pixel B/Shutterstock.com

This article was updated on 8 July 2024

Its low density and high specific strength (approximately 130 kNm/kg) make it an excellent
choice for industrial applications. Mg ranks third in usage as a structural material after steel
and aluminum and is the most reactive among engineering materials.1

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Magnesium Alloys: Trends, Applications, and New Technologies

Current Market Dynamics

Mg is vital to the global economy, with a market size estimated at slightly over USD 4.3
billion in 2021. Experts project that the global Mg market will reach USD 6.4 billion within
the next five years. Mg's widespread use in the automotive, aircraft, and manufacturing
sectors underscores its economic importance.

Several factors influence Mg prices and the global market. Controlling about 85% of the
worldwide supply, China's production significantly impacts pricing trends and supply
dynamics. Chinese companies have maintained low Mg prices, hindering new market
entrants and solidifying China’s market position.2

Disruptions in Chinese manufacturing processes or policies can lead to substantial price

fluctuations and supply chain disturbances.3 For example, a production slowdown in China
due to high coal prices and energy rationing led to record magnesium prices and significant
global supply chain distortions.

The United States Geological Survey (USGS) in 2022 reported that only one U.S. company
produced Mg via an electrolytic process, extracting it from the Great Salt Lake brines. The
primary use of Mg metal, accounting for 45 % of consumption, was in castings, primarily for
the automotive industry.4

From 2017 to 2021, the production of magnesium in the United States steadily decreased
from 112 thousand metric tons to 98 thousand metric tons. During the same period, the
annual average price of magnesium increased from $2.15 to $3.90 per pound.4

Secondary magnesium from old scrap collected in the U.S. amounted to about 29,000 tons
in 2021, with 57 % recovered from aluminum-base alloys and 43 % from magnesium-base
castings, ingots, and other products.

The U.S. International Trade Commission (USITC) in 2023 stated that the continuation or
recurrence of material injury is likely if the existing antidumping duty on pure Mg from China
is revoked. Thus, the order on imports from China remains in place.5

Application and Growth Areas

Despite the availability of various metals and
polymers, Mg remains popular due to its superior Discover More:
properties, such as improved thermal and Advancing AA2024 Aluminum Alloy:

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Magnesium Alloys: Trends, Applications, and New Technologies

electrical conductivity, shock and vibration Microstructure to Mechanics

absorption, and damping attributes.

During World War II, Mg was used in military aircraft construction and components. Today, it
continues to be used in aircraft engine transmission castings and landing gears. Recent
efforts to address Mg's flammability have increased its use in airplane cabins.

In the automotive sector, Mg is used in powertrains, chassis, and body structures, ranking
third among metallic materials used in the industry. Alloy cast Mg is in high demand due to
its superior qualities. Applications include instrument panel structures, cross-car beams,
roof frames, and seat frames, especially in areas where weight reduction is crucial.6

High-pressure die-casting (HPDC) is a popular method for producing industrial-grade Mg

alloys due to its superior surface quality. Mg-Rare Earth-based alloys have shown
significant advancements in heat resistance, with superior high-temperature properties
compared to other magnesium systems.

A newly developed HPDC Mg-RE-based alloy has demonstrated excellent heat resistance,
with a tensile strength of 229 MPa at 200 °C and a minimum creep rate of 1.76 × 10−10 s−1,
which is a significant improvement over other Mg alloys. This makes it suitable for high-
temperature applications in the automotive and aerospace sectors.6

New Sources and Production Technologies

Located 150 km southeast of Melbourne, Latrobe Magnesium (ASX: LMG) has finalized the
construction and commissioning of its 1,000-tons-per-annum Stage 1 demonstration plant.
The plant is designed to convert environmental waste products into Magnesium Oxide
(MgO) for use in various industries.

Latrobe Mg's patented hydrometallurgical extraction and thermal reduction technology is

the only process capable of extracting Mg from brown coal fly ash and ferro-nickel slag
tailing feedstocks. This novel, sustainable process converts waste products into reusable
Mg metal.7

Governments have realized the importance of Mg and have started to use mining to
produce this precious metal. Verde Magnesium, a mining company, has decided to invest a
significant $1 billion in Romania.

Governments have recognized the importance of Mg and are investing in mining to produce

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Magnesium Alloys: Trends, Applications, and New Technologies

this valuable metal. Verde Magnesium, a mining company, plans to invest $1 billion in
Romania to revive a Mg mine closed ten years ago.

Approved by the Romanian government, this mine could become the first new European
Mg metal project in decades, potentially producing up to 90,000 tons annually, meeting
around 50 % of the European Union's demand. This initiative is crucial for reducing
dependency on China for Mg.8

In addition to new projects, innovative manufacturing and production processes for Mg

alloys are being researched. Recently, a new alternative to conventional additive
manufacturing techniques for Mg alloys was introduced, involving a specialized weaving
process using Mg wires. With optimized microstructures, these wires enable high-
throughput manufacturing and create porous architectures optimized for stiffness and
porosity through topology optimization.9

Using ZXM100 wires, researchers fabricated 3D woven Mg scaffolds with controlled

porosity and pore size.9 These scaffolds were coated with polylactic acid (PLA) using a dip-
coating approach, significantly improving bending strength and enhancing the mechanical
properties of the final magnesium product.

Scientists are also leveraging digital technologies such as Artificial Intelligence (AI) and
machine learning (ML) to design Mg alloys with improved corrosion resistance. With a focus
on sustainable Mg production, experts aim to establish Mg as a crucial metal for future
automotive and aerospace industries.

In the future, we can anticipate more novel, cost-effective methods of Mg production and
new Mg alloys for biomedical applications.

More from AZoM: Sustainable Materials in the Automotive Industry: Leading

Innovators

References and Further Reading

[1] Prasad, S,. et al. (2022). The role and significance of Magnesium in modern day
research-A review. Journal of Magnesium and alloys. doi.org/10.1016/j.jma.2021.05.012

[2] Coyne, J. (2022). Magnesium market highlights continuing fragility of global supply

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Magnesium Alloys: Trends, Applications, and New Technologies

chains. [Online] ASPI. Available at: https://www.aspistrategist.org.au/magnesium-market-

highlights-continuing-fragility-of-global-supply-chains/ (Accessed on June 08, 2024)

[3] Shanghai Metal Market (2024). The Impact of Magnesium Prices on the Global Market.
[Online] Shanghai Metal Market. Available at:
https://news.metal.com/newscontent/102722083/The-Impact-of-Magnesium-Prices-on-the-
Global-Market (Accessed on June 07, 2024)

[4] U.S. Geological Survey. (2022). Magnesium Metal. [Online] USGS. Available at:
https://pubs.usgs.gov/periodicals/mcs2022/mcs2022-magnesium-metal.pdf
(Accessed on June 08, 2024)

[5] United States International Trades Commission. (2023). USITC Makes Determination In
Five-Year (Sunset) Review Concerning Pure Magnesium From China. [Online] United
States International Trades Commission. Available at:
https://www.usitc.gov/press_room/news_release/2023/er0426_63837.htm (Accessed on
June 09, 2024]

[6] Bai, Y., et al. (2022). New HPDC Mg-RE based alloy with exceptional strength and creep
resistance at elevated temperature. Materials Science and Engineering.
doi.org/10.1016/j.msea.2022.142921

[7] Innovation News Network. (2024). Latrobe Magnesium: Demonstrating sustainable

magnesium production from fly ash. [Online] Innovation News Network. Available at:
https://www.innovationnewsnetwork.com/demonstrating-sustainable-magnesium-
production-from-fly-ash/48203/ (Accessed on June 10, 2024)

[8] Mining. (2024). Verde Magnesium granted mining rights in Romania. [Online] Mining.
Available at: https://www.mining.com/verde-magnesium-granted-mining-rights-in-romania/
(Accessed on June 10, 2024)

[9] Yang, Y., et al. (2023). Research advances of magnesium and magnesium alloys
worldwide in 2022. Journal of Magnesium and Alloys. doi.org/10.1016/j.jma.2023.07.011

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Article Revisions
Jul 8 2024 - This article was updated on 8th July 2024

Written by

Ibtisam Abbasi
Ibtisam graduated from the Institute of Space Technology, Islamabad with a B.S. in Aerospace
Engineering. During his academic career, he has worked on several research projects and has
successfully managed several co-curricular events such as the International World Space Week
and the International Conference on Aerospace Engineering. Having won an English prose
competition during his undergraduate degree, Ibtisam has always been keenly interested in
research, writing, and editing. Soon after his graduation, he joined AzoNetwork as a freelancer to
sharpen his skills. Ibtisam loves to travel, especially visiting the countryside. He has always been
a sports fan and loves to watch tennis, soccer, and cricket. Born in Pakistan, Ibtisam one day
hopes to travel all over the world.

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