The goals of the development of new continuous casting processes for magnesium alloys are on the one hand focused on quality improvement, eg. surface and microstructure, and on the other hand incorporate cost reductions since today the comparatively complex process chain prevents a wider usage of wrought alloy applications. For extrusion and forging purposes, at the Institute of Materials Science four UDC (upward-direct chill) caster-prototypes with billet diameters from 40 to 203 mm were constructed, built and tried in extensive experiments. Though, for the sheet metal production rectangular flat profiles with improved surface proper-ties are needed. Hence a strip casting process, similar to the Hazellet principle, was developed in laboratory scale and then optimized according to the properties of magnesium melts. It was thus possible to show the large potential of this technique. Within this contribution the con-struction and the casting parameters of both casting machines are being displayed. The cast products made of the standard alloy AZ31 and alternative alloys of the MgZnRE system, were analyzed regarding their quality properties. Finally, the deformation behavior of cast billets and strips was compared exemplary in the rolling process for magnesium sheets. Derived from the results in laboratory scale, the cost saving potential for an industrial application of both casters was estimated.
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