Twin-roll casting plant Mg wire

In order to complement the field of research on the production and processing of magnesium products, the Institute has had a pilot research facility for the continuous production of magnesium long products using the twin-roll casting process since the end of 2017.

The technology developed and patented at the TU Bergakademie Freiberg, which has been researched at the Institute for magnesium flat products since the early 2000s, was transferred to the manufacture of wires. With the pilot plant that has now been constructed, which was funded to the tune of five million euros by the Saxon Ministry of Science and the Arts via the European Regional Development Fund (ERDF), the light metal can be produced in an energy- and resource-efficient manner for the first time anywhere in the world via twin-roll casting.

Magnesium wires can be used, for example, in biomedicine or in joining technology in the form of screws or welding rods.



The plant consists of an electrically heated melting furnace with a capacity of 400 kg magnesium. The melt is then transferred to a headbox, from where the molten metal is transferred to the casting nozzle and then to the rolling gap. If the melt is poured between the two rotating, water-cooled rolls into the oval groove, it begins to solidify from the outside to the inside and undergoes its first transformation. Wires and rods up to a diameter of 20 centimeters with a length of up to eight meters are produced continuously.

The twin-roll casting technology saves process steps and thus material and energy costs, while at the same time improving productivity and cost-effectiveness.

The pilot plant planned for the technology development has been developed at the Institute for Metal Forming since 2016 and has been constructed by the special plant manufacturer hpl Neugnadenfelder Maschinenfabrik. Current research activities include the AZ31 alloy, but the range of investigations is to be extended to include rare earth alloys (WE43, WZ73) and calcium-containing alloys (ZAX210, MX20) in addition to the AZ series.