A single step sustainable manufacturing technology and synergy map for producing high performance magnesium alloy sheets

Large scale enterprises across the globe demands an innovative, economical and efficient manufacturing process that ensures the sustainable production of Magnesium (Mg) sheets. The present research establishes the impact of temperature, load and speed on mechanical properties and manufacturability of Mg sheets processed via single step large strain rolling (LSR) with varying deformation zone length conditions. The science of temperature-dependant deformation behaviour and defect formation characteristics is comprehensively studied using extensive experimentation and finite element method (FEM) simulations to provide in-depth insights into dynamic phenomena. A new scientific outcome of identifying critical condition for transitioning twin mode of deformation to slip dominant deformation is established for Mg. The processing windows revealing strength-ductility trade-off/synergy zones using synergy index are established to provide a guideline for producing application specific Mg sheets. The scientific knowhow and the underlying mechanisms leading to extraordinary synergy index of these Mg sheets have been unravelled for the first time. This single step sustainable manufacturing technology opens a new pathway for producing high performance Mg sheets and exhibits a promising potential to be scaled up for industrial use.