kokoMag

Development and evaluation of a corrosion-protected, non-combustible carbon fibre reinforced magnesiummaterial for aerospace applications

Traditional designs using light metals are increasingly reaching their limits in terms of the required material properties and strength, while at the same time there is a desire for better resource consumption, thinner wall thicknesses and reduced material usage. The system weight of components plays an enormous role in aviation in particular. The overall objective of the kokoMag project was therefore the development and validation of a corrosion-protected, non-flammable carbon fibre-reinforced magnesium material (CF/Mg) for structural components in the cabin and cargo area of aircrafts. Due to its high mass-specific stiffness and strength, CF/Mg offers enormous lightweight construction potential with direction-dependent composite properties that can be specifically adjusted. Together with the Institute of Materials Science (ifWW), the development of non-combustible CF/Mg composites with customised corrosion protection systems was undertaken (Fig.1). The challenge was to modify the manufacturing process for non-combustible Mg-Eco alloys to produce the composite materials. Based on this, various layers were applied to the CF/Mg substrate using innovative thermal spraying processes, their adhesive strength and the entire material composite were tested for corrosion resistance and flammability. Finally, solutions were identified for using the new material system for further development approaches.