Selected processing for non-equilibrium light alloys and products

• US 6,544,357 B1
• Filed: 01/31/1997
• Issued: 04/08/2003
• Est. Priority Date: 08/01/1994
• Status: Expired due to Fees

• Current Assignee: Franz Hehmann
• Original Assignee: Franz Hehmann
• Inventors: Hehmann, Franz, Weidemann, Michael
• Primary Examiner(s): Ip, Sikyin
• Application Number:
  US08/776,382
• Time in Patent Office: 2,258 Days
• Field of Search: 148/420, 148/666, 148/667, 420/405, 420/406, 420/407, 420/408, 420/409, 420/410, 420/411, 420/412, 420/413, 420/414
• US Class Current: 148/420
• CPC Class Codes: C23C 14/14 Metallic material, boron or silicon
• CPC Class Codes: C23C 14/22 characterised by the process of coating
• CPC Class Codes: Y02T 50/60 Efficient propulsion technologies, e.g. for aircraft
• CPC Class Codes: Y10T 137/85938 Non-valved flow dividers

Abstract

A new class of light or reactive elements and monophase α′-matrix magnesium- and aluminum-based alloys with superior engineering properties, for the latter being based on a homogeneous solute distribution or a corrosion-resistant and metallic shiny surface withstanding aqueous and saline environments and resulting from the control during synthesis of atomic structure over microstructure to net shape of the final product, said α′-matrix being retained upon conversion into a cast or wrought form. The manufacture of the materials relies on the control of deposition temperature and in-vacuum consolidation during vapor deposition, on maximized heat transfer or casting pressure during all-liquid processing and on controlled friction and shock power during solid state alloying using a mechanical milling technique. The alloy synthesis is followed by extrusion, rolling, forging, drawing and superplastic forming for which the conditions of mechanical working, thermal exposure and time to transfer corresponding metastable α′-matrix phases and microstructure into product form depend on thermal stability and transformation behavior at higher temperatures of said light alloy as well as on the defects inherent to a specific alloy synthesis employed. Alloying additions to the resulting α′-monophase matrix include 0.1 to 40 wt. % metalloids or light rare earth or early transition or simple or heavy rare earth metals or a combination thereof. The eventually more complex light alloys are designed to retain the low density and to improve damage tolerance of corresponding base metals and may include an artificial aging upon thermomechanical processing with or without solid solution heat and quench and annealing treatment for a controlled volume fraction and size of solid state precipitates to reinforce alloy film, layer or bulk and resulting surface qualities. Novel processes are employed to spur production and productivity for the new materials.

Claims

1. A magnesium-based alloy comprising at least one alloying element or alloying addition in a solid solution or amorphous phase,

said magnesium-based alloy having a porosity-free microstructure which comprises homogeneous distribution of at least one solute atom of at least one alloying element or alloying addition, wherein said homogeneous distribution comprises a distance between two like atoms of said at least one solute atom, wherein said distance ranges from a minimum value of 1 atomic or ionic spacing to a maximum of 498 atomic or ionic spacings on an average length scale conforming to Σ

(N×

d_i×

c_i)/n,

wherein N is a number of alloy matrix atoms of a number n of components i of an alloy matrix comprising atomic or ionic spacings d_i with a concentration c_i, wherein components i are magnesium and said at least one alloying element or alloying addition,

said porosity-free microstructure is obtained by consolidation of an alloy which is one or more of the following;

A. a vapor deposited alloy having a columnar grain structure without boundary phases on a substrate chilled by a chill medium,

B. a mechanically alloyed powder having a homogeneous one-phase or essentially one-phase non-equilibrium structure without an undissolved constituent in a crystalline or amorphous solid solution and a deformation energy mechanically controlled by shock,

C. a rapidly solidified alloy comprising a planar or partitionless growth without segregation from a cellular growth or from a dendritic growth sustained by a heat transfer comparable to a wheel speed ranging from 3.5 to 7.0 km/min afforded by a wheel of a highly conductive material under a helium atmosphere,

D. a cast product without microalloyed constituents on grain boundaries and having a concentration of the at least one alloying element or alloying addition within an equilibrium solid solubility range of close-packed hexagonal magnesium and a maximum content of 0.0005% Ni, 0.0013% Fe and 0.0005% Cu,

E. an ingot cast product without microalloyed constituents on grain boundaries and having a concentration of the at least one alloying element or alloying addition within an equilibrium solid solubility range of close-packed hexagonal magnesium and a maximum content of 0.0005% Ni, 0.0013% Fe and 0.0005% Cu and

F. a spray deposition to produce a micrograined alloy without microalloyed constituents on grain boundaries and having a concentration of the at least one alloying elements or alloying addition within an equilibrium solid solubility range of close-packed-hexagonal magnesium and a maximum content of critical impurities by weight of 0.0005% Ni, 0.0013% Fe and 0.0005% Cu and an inclusion.

2. The magnesium-based alloy according to claim 1, wherein said microstructure is one or more of the following:

A. a microstructure without a corrosion-rate controlling Fe inclusion,

B. a microstructure without a corrosion-rate controlling pore, or

C. a supersaturated microstructure.

3. The magnesium-based alloy according to claim 1, wherein the microstructure of A-E in claim 1 is a one-phase microstructure and/or a supersaturated one-phase microstructure.

4. The magnesium-based alloy according to claim 1, wherein the microstructure of A-C in claim 1 is one or more of the following:

A. a β

-monophase non-equilibrium or amorphous microstructure,

B. a non-equilibrium crystalline phase microstructure or

C. a non-equilibrium amorphous phase microstructure.

5. The magnesium-based alloy according to claims 1, wherein a majority of atoms in contact with impurity atoms in said alloy are magnesium and said at least one alloying element or alloying addition of the vapor deposited alloy or of the mechanically alloyed powder is selected from the group consisting of Fe and oxygen.

6. The magnesium-based alloy according to claim 1, wherein said microstructure comprises a solid solution which is selected from the group consisting of a solid solution of close-packed-hexagonal magnesium, an equilibrium close-packed-hexagonal solid solution, a supersaturated equilibrium close-packed-hexagonal solid solution and a supersaturated close-packed hexagonal solid solution.

7. The magnesium-based alloy according to claim 1, wherein said microstructure has a non-equilibrium phase which is selected from the group consisting of a homogeneous non-equilibrium phase, an extended solid solution of close-packed hexagonal magnesium, a passivating extended solid solution, a terminal solid solubility extension, a quasi-crystalline phase, a nanocrystalline phase, a non-equilibrium crystalline phase, a structurally homogeneous non-equilibrium phase, metastable crystalline phase, a non-equilibrium amorphous phase, a metastable amorphous phase and a non-equilibrium matrix phase.

8. The magnesium-based alloy according to claim 1, wherein said consolidation is selected from the group consisting of:

A. in-situ consolidation of said vapor deposited alloy in a vacuum on said substrate,

B. consolidation of said mechanically alloyed powder in an inert atmosphere into a bulk alloy,

C. consolidation of said rapidly solidified alloy selected from the group consisting of degassing, pressing, cold pressing, cold isotactic pressing, hot pressing, hot isotactic pressing, extrusion, rolling, forging, direct powder forging, explosive consolidation, shock consolidation, drawing and superplastic forming,

D. consolidation of said cast product by a pressure die-casting into a wall thickness ranging from 0.2 to 20 mm and a solid solution heat treatment after said pressure die casting,

E. consolidation of said ingot cast product by extrusion into a bar or rod or by fabrication into a forged product, a sheet, a plate, or a foil and a solid solution heat treatment before or after or before and after said extrusion or fabrication, and

F. consolidation of said micrograined alloy by an extrusion into a bar or rod or by fabrication into a forged product, a sheet, a plate, or a foil and a solid solution heat treatment before or after or before and after said extrusion or fabrication.

9. The magnesium-based alloy according to claim 1, wherein the microstructure comprises one or more of the following:

A. a one-phase alloy matrix,

B. a non-equilibrium metastable one phase matrix,

C. a homogeneous non-equilibrium one phase matrix,

D. a passive close-packed-hexagonal one-phase matrix

E. a non-equilibrium alloy matrix,

F. a matrix being free of a second phase dispersion being harmful to corrosion resistance

G. no second phases from overaging, or

H. a solid state precipitation.

10. The magnesium-based alloy according to claim 9, wherein the solid state precipitation is selected from the group consisting of

A. a solid state precipitation at a distinctively lower temperature than a temperature of transformation of a metastable Mg-rich phase into equilibrium phases,

B. a solid state precipitation in an underaged condition and simultaneous retention of an extended solid solubility,

C. a solid state precipitation supported by aluminum and alkaline earth metals while at least one rare earth metal is essentially held in solid solution,

D. a precipitation of fme Al₂Ca-precipitate at temperatures where dissolved rare earth metals remain unaffected,

E. a precipitation which is microgalvanized less nobel than a non-equilibrium magnesium alloy matrix,

F. a microcathodic surface precipitation,

G. a microgalvanically inert second phase dispersion,

H. a precipitation of a nanodispersion of essentially round-shaped precipitates,

I. a thermally stable solid state precipitation of size ranging from 10-15 nm,

J. a solid state precipitation of aluminides,

K. a solid state precipitation of silicides, or

L. a solid state precipitation of borides.

11. The magnesium-based alloy according to claim 10, wherein said aluminides are selected from the group consisting of rare earth aluminides, titanium aluminides, Al₂(CeMg), Al_xMn_y, Alx_xZr_y and Al_aFe_bCe_c.

12. The magnesium-based alloy according to claim 10, wherein said suicides are selected from the group consisting of aluminum rich silicides, Al_aTM_bSi_c, complex silicides, and Mg₂CeSi₂.

13. The magnesium-based alloy according to claim 10, wherein said microgalvanically inert second phases are selected from the group consisting of Mg_xRE_y, Al_xAE_y, Al_xRE_y and (Al_aMg_a)_x(AE_cRE_d)_y, wherein AE=Ca, Sr or Ba and RE=rare earth metal.

14. The magnesium-based alloy according to claim 1, wherein said microstructure exhibits one or more of the following:

A. an activation energy exceeding a value of 100 kJ/mol K for phase transformation from a metastable metallic matrix phase or into equilibrium phases,

B. a thermally stable product retaining an atomic homogeneity,

C. a refined grain by a solidification or a consolidation selected from the group consisting of a cold extrusion, cold forging or cold rolling,

D. a hardening or strengthening selected from the group consisting of solid solution hardening dislocation hardening and grain boundary hardening,

E. a precipitation or age hardening response,

F. a passivity promoter against formation of an Mg(OH)₂ surface film,

G. a specific density lighter than aluminum,

H. an enhanced hydrogen storage capacity involving Ni and Pd, or

I. a precipitation without affecting a passivity due to dissolution of the at least one alloying element or alloying addition in close-packed hexagonal magnesium.

15. The magnesium-based alloy according to claim 8, wherein said consolidation is carried out according to one or more of the following:

A. at a temperature below the transformation temperature of an extended solid solution or a metastable crystalline phase or a metastable amorphous phase of a thermally stable solid solution into formation of an equilibrium microstructure,

B. at a temperature 100°

to 300°

C. lower than the temperature of an ingot processed Mg alloy,

C. at a temperature in the range from 65°

to 150°

C.,

D. at a temperature in the range from 50°

to 200°

C.,

E. at a temperature in the range from 50°

to 250°

C., or

F. at a temperature around 200°

C.

16. The magnesium-based alloy according to claim 8, wherein said consolidation for a cast product or for an ingot cast product is at a temperature of an equilibrium solid solution.

17. The magnesium-based alloy according to claim 1, wherein the at least one alloying element or alloying addition of the vapor deposited alloy is selected from the group consisting of:

(a) a light rare earth metal which is selected from the group consisting of;

0.1 to 30% by weight of La,

0.1 to 30% by weight of Ce,

0.1 to 30% by weight of Pr,

0.1 to 32% by weight of Nd,

0.1 to 35% by weight of Sm, and

0.2 to 35% by weight of a light rare earth misch-metal,

(b) a heavy rare earth metal which is selected from the group consisting of;

0.1 to 15 at. % Gd,

0.1 to 15 at. % Dy and

0.1 to 10 at. % Ho,

(c) a scandium, yttrium or europium which is selected from the group consisting of;

0.1 to 30% by weight of Sc,

0.2 to 30% by weight of Y and

0.2 to 30% by weight of Y and Eu,

(d) a early transition metal which is selected from the group consisting of;

0.1 to 40% by weight of Ti,

0.1 to 30% by weight of Zr,

0.1 to 30% by weight of Hf,

0.1 to 25% by weight of Ta,

0.1 to 25% by weight of W,

0.1 to 20% by weight of Mo,

0.1 to 25% by weight of Nb,

0.1 to 30% by weight of Cr,

0.1 to 40% by weight of V,

0.1 to 30% by weight of Mn and

0.1 to 20% by weight of Re,

(e) a metalloid or beryllium which is selected from the group consisting of;

0.1 to 35% by weight of B,

0.1 to 35% by weight of Be,

0.1 to 20% by weight of Si,

0.1 to 15% by weight of Sb and

0.1 to 35% by weight of Ge, or

(f) a metal which is selected from the group consisting of;

0.2 to 15% by weight of Al and

0.2 to 15% by weight of Ga.

18. The magnesium-based alloy according to claim 1, wherein the at least or alloying addition of the mechanically alloyed powder is selected from the group consisting of:

(a) a light rare earth metal which is selected from the group consisting of;

0.1 to 40% by weight of La,

0.1 to 40% by weight of Ce,

0.1 to 40% by weight of Pr,

0.1 to 40% by weight of Nd,

0.1 to 40% by weight of Sm, and

0.2 to 35% by weight of a light rare earth misch-metal,

(b) a heavy rare earth metal which is selected from the group consisting of;

0.1 to 15 at. % Gd,

0.1 to 15 at. % Dy, and

0.1 to 10 at. % Ho,

(c) a scandium, yttrium, or europium which is selected from the group consisting of;

0.1 to 20% by weight of Sc,

0.2 to 40% by weight of Y, and

0.2 to 40% by weight of Y and Eu,

(d) an early transition metal which is selected from the group consisting of;

0.1 to 40% by weight of Ti,

0.1 to 30% by weight of Zr,

0.1 to 30% by weight of Hf,

0.1 to 20% by weight of Ta,

0.1 to 40% by weight of W,

0.1 to 20% by weight of Mo,

0.1 to 25% by weight of Nb,

0.1 to 30% by weight of Cr,

0.1 to 40% by weight of V,

0.1 to 30% by weight of Mn,

0.1-20% by weight of Pd, and

0.1-60% by weight of Ni,

(e) a metalloid or beryllium;

0.1 to 30% by weight of B,

0.1 to 30% by weight of Be,

0.1 to 30% by weight of Si,

0.1 to 25% by weight of Sb, and

0.1 to 25% by weight of Ge, or

(f) a metal which is selected from the group consisting of

0.2 to 20% by weight of Al and

0.2 to 25% by weight of Ga.

19. The magnesium-based alloy according to claim 1, wherein said at least one alloying element or alloying addition of the rapidly solidified alloy is selected from the group consisting of:

0.1 to 25% by weight of La,

0.1 to 25% by weight of Ce,

0.1 to 25% by weight of Pr,

0.1 to 28% by weight of Nd,

0.1 to 30% by weight of Sm,

0.2 to 14% by weight of Y,

0.2 to 14% by weight of Y and Eu,

0.2 to 30% by weight of a light rare earth misch-metal,

0.2 to 15% by weight of Al,

0.1 to 10% by weight of Mn, or

0.1 to 5% by weight of Zr.

20. The magnesium-based alloy according to claim 1, wherein said at least alloying element or alloying addition of the rapidly solidified alloy is selected from the group consisting of:

0.1 to 20% by weight of Sc,

0.1 to 7% by weight of Sm,

0.1 to 5 at. % Gd,

0.1 to 7 at. % Dy,

0.1 to 6 at. % Ho,

0.1 to7at. % Tm,

0.1 to 8 at. % Er,

0.1 to 9 at. % Lu,

0.1 to 6 at. % Tb,

0.1 to 2.5% by weight of Zr, or

0.1 to 3.0% by weight of Mn.

21. The magnesium-based alloy according to claim 1, wherein said at least alloying element or alloying addition of the cast product or the ingot cast product or the micrograined alloy is selected from the group consisting of:

0.1 to 20% by weight of Sc,

0.1 to 7% by weight of Sm,

0.1 to 5 at. % Gd,

0.1 to 7 at. % Dy,

0.1 to 6 at. % Ho,

0.1 to 7 at. % Tm,

0.1 to 8 at. % Er,

0.1 to 9 at. % Lu,

0.1 to 6 at. % Tb,

0.1 to 2.5% by weight of Zr, or

0.1 to 3.0% by weight of Mn.

22. The magnesium-based alloy according to claims 1, wherein said alloy retains metallic glamour after subjecting said alloy to at least one corrosion test selected from the group consisting of salt fog, salt spray, immersion, HF corrosion test, H₃PO₄ corrosion test, Machu test and modified Machu test.

23. The magnesium-based alloy according to claim 1, wherein melting or mechanical alloying for preparation of said alloy is carried out in a crucible or a milling container made of a refractory metal selected from the group consisting of Hf, V, Ta, Nb, Mo, W, Cr, Re, and Zr or made of a refractory metal-based alloy.

24. The magnesium-based alloy according to claim 1, wherein said alloy has one or more of the following:

A. a metallic shiny solid solution after etching with HF or H₃PO₄,

B. a featureless microstructure comprising a segregation-free solid solution alloy or

C. a metallic shiny surface zone comprising either an equilibrium close-packed-hexagonal magnesium solid solution or a supersaturated solid solution of the close-packed-hexagonal magnesium.

25. The magnesium-based alloy according to claim 1, wherein said alloy comprises a minor alloying addition selected from the group consisting of Zn, Ca, Sr, and Ba.

26. The magnesium-based alloy according to claim 1, wherein said vapor deposited alloy or said mechanically alloyed powder comprises a minor alloying addition selected from the group consisting of Sn and Pb.

27. The magnesium-based alloy according to claim 1, wherein the alloy exhibits a higher order extended solid solution to passivate one or more complex magnesium alloys.

28. The magnesium-based alloy according to claim 27, wherein the one or more complex magnesium alloys comprises one or more of the following combinations:

Mg—

RE—

Al (RE=rare earth metal or a misch-metal).

Ag—

RE—

AE (alkaline earth metal Ca, Sr, Ba).

Mg—

RE—

Zn.

Mg—

RE—

met (Si, Ge, B, Sb).

Mg—

RE—

Al—

AE, where Al=2 to 3*AE and AE<

<

RE.

Mg—

RE—

Al—

met,

Mg—

RE—

Al—

TM(transitional),where Al=2 to 4*TM and TM <

<

RE,

Mg—

RE—

TM, where RE>

TM,

Mg—

RE—

Al—

TM—

met using one or more TM,

Mg—

RE—

Al—

TM—

met, where Al>

TM>

met using one or more TM,

Mg—

TM—

RE,

Mg—

TM—

Al,

Mg—

TM—

TM,

Mg—

TM—

TM—

RE,

Mg—

TM—

TM—

Al,

Mg—

TM—

Al—

met,

Mg—

TM—

Al—

AE,

Mg—

TM—

Al—

RE, where Al—

RE and TM>

>

Al,

Mg—

met,

Mg—

met—

TM,

Mg—

met—

RE,

Mg—

met-TM—

TM,

Mg—

met-TM—

RE,

Mg—

met—

TM—

Al,

Mg—

met-TM—

TM—

RE or

Mg—

met—

TM—

RE—

Al.

29. The magnesium-based alloy according to claim 1, wherein the alloy exhibits one or more of the following:

an ordered atomic arrangement, a short range order, an ordered structure or an ordered phase.

30. The magnesium-based alloy according to claim 1, wherein the alloy has the following:

A. a homogeneous distribution of the at least one alloying element on a solid magnesium-based surface,

B. a topologically or spatially homogeneous distribution of non-magnesium atoms in all surface planes,

C. a homogeneity which is microstructural homogeneity, phase homogeneity, atomic homogeneity, chemical homogeneity or structural homogeneity, or

D. a homogeneous depletion surface zone of a less noble constituent.

31. The magnesium-based alloy according to claim 1, wherein the vapor deposited alloy or the rapidly solidified alloy exhibits one or more of the following:

A. featureless columnar grain structure without microsegregation,

B. featureless columnar grain structure without response to indicate microsegregations by chemical etching, or

C. featureless columnar grain structure with the at least one alloying addition in an extended close-packed-hexagonal magnesium-base solid solution without microsegregation.

32. The magnesium-based alloy according to claim 1, further comprising one or more of the following:

A. a surface oxide selected from the group of a MgO surface oxide, a MgO-base surface oxide, an amorphous oxide, a MgO surface oxide film and an alloyed MgO-surface film generated by an alloyed monophase matrix,

B. an oxide formation comprising a passivity promoter,

C. an oxide formation comprising a passivity promoter having a high metal oxygen bond strength Δ

H_abs,

D. an oxide formation of a passivity promoter having a high metal oxygen bond strength Δ

H_abs and a low like-like metal bond strength ε

_M-M

E. an oxide-modifying and/or stabilizing element homogeneously incorporated in the resulting modified oxide,

F. a homogeneous distribution of up to three of the at least one alloying element or alloying addition in a cation sublattice of an alloyed MgO-base surface oxide or

G. a surface oxide with a topology selected from the group of coherent, dense, tight and homogeneous topology.

33. The magnesium-based alloy according to claim 1, further comprising one or more of the following:

A. an alloyed MgO-surface film without permeability on both an atomic and a microstructural scale,

B. a surface oxide having a topological coherency or a topological non-permeability,

C. a non-permeable surface film,

D. passivation of a MgO-surface oxide film,

E. passivation by an extended solid solubility,

F. an alloyed MgO-surface film without permeability on both an atomic and a microstructural scale, generated by an alloyed monophase matrix with least microgalvanic gradients,

G. a thin and metallic shiny passive film, or

H. a passivated microgalvanic gradient.

34. The magnesium-based alloy according to claims 1, further comprising one or more of the following:

A. a self-healing passive surface oxide film or

B. a self-healing surface film to protect interior or bulk material.

35. The magnesium-based alloy according to claim 1, said alloy having one or more of the following:

A. prismatic slip in a close-packed-hexagonal magnesium-matrix supersaturated with said at least one alloying element,

B. a prismatic slip induced by major alloying with early transition metals, yttrium and light rare earth metal, or

C. increased thermal stability, modulus of elasticity and resistance to corrosion of a solid non-equilibrium magnesium phase due to electronic structure obtained by addition of a refractory metal selected from the group of Ti, Nb, Ta, Mo, W, Zr, Cr, Mn and Hf.

36. The magnesium-based alloy according to claim 1, further comprising one or more of the following:

A. a modification of a MgO-surface film forming a Pilling-Bedworth ratio of at least unity protecting a metallic interior,

B. a homogeneous surface oxide with a Pilling-Bedworth ratio around and above unity protecting a metallic interior, or

C. an amorphous oxide without grain boundary diffusion paths.

37. The magnesium-based alloy according to claim 1, further comprising one or more of the following:

A. an alkaline earth element providing an electron pressure on the MgO surface film via a size regime of solid state precipitates,

B. an alloying element substituting magnesium atoms in a MgO—

surface crystal lattice and comprising valencies >

2, or

C. an n-conduction or an increased electron concentration, or

D. an oxide surface repelling O<sup>−

−</sup>

ions.

38. The magnesium-based alloy according to claim 17, wherein the vapor deposited alloy comprises further a ternary or higher order alloying addition of the group consisting of

A. 0.1 to 16 wt. % Al,

B. 0.0 to 8 wt. % Ca, Sr or Ba,

C. 0.0 to 4 wt. % Zn, In, Sn or Pb,

D. 0.0 to 10 wt. % Si, Ge, B, Be or Sb, and

E. 0.0 to 12 wt. % V, Ti, Zr, Mn, Cr, Nb, Mo, Hf, Re, W or Ta.

39. The magnesium-based alloy according to claim 18, wherein the mechanically alloyed powder comprises further a ternary or higher order alloying addition of the group consisting of:

A. 0.1 to 16 wt. % Al,

B. 0.0 to 8 wt. % Ca, Sr or Ba,

C. 0.0 to 4 wt. % Zn, In, Sn or Pb,

D. 0.0 to 10 wt. % Si, Ge, B, Be or Sb, and

E. 0.0 to 12 wt. % V, Ti, Zr, Mn, Cr, Nb, Mo, Hf, Re, W or Ta.

40. The magnesium-based alloy according to claim 17, wherein the vapor deposited alloy comprises further a ternary or higher order alloying addition of the group consisting of:

A. 0.1 to 30 wt. % V, Ti, Zr, Mn, Cr, Nb, Mo, Hf, Re, W or Ta,

B. 0.3 to 30 wt. % of a combination of two or three metals of A.,

C. up to 15 wt. % Al,

D. 0.0 to 12 wt. % Ce, La, Pr, Nd, Sm, Gd, Dy, Ho, Er or a misch-metal, and

E. 0.1 to 4 wt. % Si, Ge, B, Be or Sb.

41. The magnesium-based alloy according to claim 18, wherein the mechanically alloyed powder comprises further a ternary or higher order alloying addition of the group consisting of:

A. 0.1 to 30 wt. % V, Ti, Zr, Mn, Cr, Nb, Mo, Hf, Re, W or Ta,

B. 0.3 to 30 wt. % of a combination of two or three metals of A.,

C. up to 15 wt. % Al,

D. 0.0 to 12 wt. % Ce, La, Pr, Nd, Sm, Gd, Dy, Ho, Er or a misch-metal, and

E. 0.1 to 4 wt. % Si, Ge, B, Be or Sb.

42. The magnesium-based alloy according to claim 17, wherein the vapor deposited alloy comprises further a ternary or higher order alloying addition of the group consisting of:

A. 0.2 to 25 wt. % Ce, La, Pr, Nd, Sm, Y or a misch-metal,

B. 0.1 to 20 wt. % V, Ti, Zr, Mn, Cr, Nb, Mo, Hf, Re, W or Ta,

C. 0.0 to 10 wt. % Al, and

D. 0.0 to 8 wt. % Ca, Sr or Ba.

43. The magnesium-based alloy according to claim 18, wherein the mechanically alloyed powder comprises further a ternary or higher order alloying addition of the group consisting of:

A. 0.2 to 25 wt. % Ce, La, Pr, Nd, Sm, Y or a misch-metal,

B. 0.1 to 20 wt. % V, Ti, Zr, Mn, Cr, Nb, Mo, Hf, Re, W or Ta,

C. up to 10wt. % Al, and

D. up to 8 wt. % Ca, Sr or Ba.

44. The magnesium-based alloy according to claims 17, wherein the vapor deposited alloy comprises further a ternary or higher order alloying addition of the group consisting of:

A. 0.1 to 20 wt. % Si, B, Be or Ge, and

E. 0.0 to 15.0 wt. % V, Ti, Zr, Mn, Cr, Nb, Mo, Hf, Re, W or Ta.

45. The magnesium-based alloy according to claim 18, wherein the mechanically alloyed powder comprises further a ternary or higher order alloying addition of the group consisting of:

A. 0.1 to 20 wt. % Si, B, Be or Ge, and

H. 0.0 to 15.0 wt. % V, Ti, Zr, Mn, Cr, Nb, Mo, Hf, Re, W or Ta.

46. The magnesium-based alloy according to claim 17, wherein the vapor deposited alloy comprises a commercial magnesium engineering alloy composition selected from the group consisting of WE54, WE43, ZE63, ZE41, EZ33, EZ32, AE41, AE42, QE22, EQ21, AZ91D/E, AZ61A/B, AZ31A/B, AM20, AM50, AM60, AM-base magnesium alloy, AS41 and AS42.

47. The magnesium-based alloy according to claim 18, wherein the mechanically alloyed powder comprises a commercial magnesium engineering alloy composition selected from the group consisting of WE54, WE43, ZE63, ZE41, EZ33, EZ32, AE41, AE42, QE22, EQ21, AZ91D/E, AZ61A/B, AZ31A/B, AM20, AM50, AM60, AM-base magnesium alloy, AS41 and AS42.

48. The magnesium-based alloy according to claim 1, wherein said cast product is made by one or more of the following:

A. thin-wall casting into a wall thickness ranging from 0.2 to 20 mm and a thermomechanical treatment at temperatures in a solution heat treatment regime,

B. thin-wall casting into a wall thickness ranging from 0.2 to 20 mm and a hot forming operation at temperatures in a solution heat treatment regime,

C. thin-wall casting into a wall thickness ranging from 0.2 to 500 mm and a hot forming operation at temperatures in a solution heat treatment regime,

D. pressure-die casting into a wall thickness ranging from 0.2 to 20 mm and a thermomechanical treatment at temperatures in a solution heat treatment regime,

E. pressure-die casting into a wall thickness ranging from 0.2 to 20 mm and a hot forming operation at temperatures in a solution heat treatment regime,

F. pressure-die casting into a wall thickness ranging from 0.2 to 500 mm and a hot forming operation at temperatures in a solution heat treatment regime,

G. an ingot casting and a thermomechanical treatment at temperatures in a solution heat treatment regime,

H. an ingot casting and a hot forming operation at temperatures in a solution heat treatment regime,

I. a thin strip casting and a thermomechanical treatment at temperatures in a solution heat treatment regime,

J. a thin strip casting and at least one rolling pass, or

K. a thin strip casting by using spray forming and at least one rolling pass.

49. The magnesium-based alloy according to claim 48, wherein said cast product comprises one or more of the following in the as-solidified state:

A. a polycrystalline microstructure having high angle boundary grains and a grain size in the range from 0.2 to 10 μ

m, or

B. a transgranular intermetallic phase of a one-dimensional length scale in the range from 0.1 to 1.0 μ

m, wherein the one-dimensional length scale is a circumpherence, a diameter or a maximum one-dimensional extension.

50. The magnesium-based alloy according to claim 48, herein said cast product comprises one or more of the following after a solution heat treatment:

A. a polycrystalline microstructure having high angle boundary grains and a grain size in the range from 0.2 to 10 μ

m, or

B. a transgranular intermetallic phase of a one-dimensional length scale in the range from 0.1 to 1.0 μ

m, wherein the one-dimensional length scale is a circumpherence, a diameter or a maximum one-dimensional extension.

51. The magnesium-based alloy according to claim 48, wherein said cast product comprises one or more of the following after a thermo-mechanical treatment or a hot forming operation at temperatures in a solution heat treatment regime:

A. a polycrystalline microstructure having high angle boundary grains and a grain size in the range from 0.2 to 10 μ

m,

B. a transgranular intermetallic phase of a one-dimensional length scale in the range from 0.1 to 1.0 μ

m, wherein the one-dimensional length scale is a circumpherence, a diameter or a maximum one-dimensional extension,

C. round-shaped precipitates comprising aluminum and a transition metal,

D. round-shaped precipitates comprising aluminum and a transition metal and cerium, or

E. a nano-dispersion of round-shaped precipitates.

52. The magnesium-based alloy according to claim 1, wherein said cast product has been made by one or more of the following:

A. selecting a suitable feedstock selected from the group of commercially available high purity feedstock,

B. selecting a casting into an inert crucible material, wherein the inert crucible material is selected from the group consisting of a refractory metal, a tantalum-based material, a tungsten-based alloy and a refractory alloy and a refractory intermetallic phase, or

C. selecting a casting under an inert atmosphere, wherein the inert atmosphere is selected from the group consisting of helium, argon, hydrogen, krypton, neon, xenon and a vacuum.

53. The magnesium-based alloy according to claim 21, wherein the cast product or the ingot cast product comprises further a ternary or higher order alloying addition of the group consisting of:

A. up to 5 wt. % La, Ce, Pr, Nd, light rare earth misch-metal,

B. up to 8 wt. % Al,

C. up to 5 wt. % alkaline earth metal,

D. up to 5 wt. % Ca and up to 8 wt. % Al,

E. up to 5 wt. % Sr and up to 8 wt. % Al,

F. up to 5 wt. % Ba and up to 8 wt. % Al,

G. up to 5 wt. % Ca and up to 8 wt. % Ga,

H. up to 5 wt. % Sr and up to 8 wt. % Ga,

I. up to 5 wt. % Ba and up to 8 wt. % Ga,

J. up to 5 wt. % Zn,

K. 0.5 to 4.0 wt. % Zn for an alloy comprising yttric alloying additions,

L. up to 5 wt. % Mn, and

M. up to 2 wt. % Zn.

54. The magnesium-based alloy according to claim 1, wherein said cast product has been made by one or more of the following:

A. selecting a suitable feedstock selected from the group of commercially available high purity feedstock,

B. selecting a casting into an inert crucible material, wherein the inert crucible material is selected from the group consisting of a refractory metal, a tantalum-based material, a tungsten-based alloy and a refractory alloy and a refractory intermetallic phase,

C. selecting a casting under an inert atmosphere, wherein the inert atmosphere is selected from the group consisting of helium, argon, hydrogen, krypton, neon, xenon and a vacuum,

D. providing an artificial aging treatment,

E. providing an artificial aging treatment and a quenching in oil, water or air, or

F. providing a final annealing treatment.

55. The magnesium-based alloy according to claim 53, wherein said cast product or said ingot cast product is converted into a wrought product by one or more of the following processes:

A. extrusion,

B. rolling,

C. forging,

D. quenching, or

E. annealing.

56. The magnesium-based alloy according to claim 55, further comprising a solution heat treatment at temperatures of a solution heat treatment regime before, after or before and after said extrusion, rolling, forging or quenching process.

57. The magnesium-based alloy according to claim 56, further comprising, a second solution heat treatment.