A new class of light or reactive elements and monophase alpha'-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 alpha'-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 alpha'-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 alpha'-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.