Microscopy as a key technology in metals research
From the atomic level through to application
New CD Lab and scanning electron microscope: A bridge between science and practice
AMAG has once again demonstrated its ability to connect science and practice. At the start of 2025, the Christian Doppler Laboratory for Deformation- Precipitation Interactions in Aluminium Alloys commenced work at Montanuniversität Leoben (MUL), headed up by Dr. Irmgard Weissensteiner. A scanning electron microscope (SEM) (Figure 1) has also been installed at the Center for Material Innovation (CMI) at AMAG’s Ranshofen site. These two measures demonstrate how fundamental research and state-of-the-art measurement technology can be combined to drive innovation in the aluminium industry. Together, they provide a basis for sustainable aluminium alloys, supporting the transfer of new insights and their application in industrial practice.
The Christian Doppler Laboratory: Fundamental research for sustainable innovations
The Christian Doppler Laboratory for Deformation-Precipitation Interactions in Aluminium Alloys, in which AMAG rolling GmbH is an active partner, is a logical continuation of the CD Laboratory for Advanced Aluminium Alloys led by Prof. Stefan Pogatscher and the Aluminium Microstructure Analysis Gainhub. It also serves as a further example of the successful collaboration between AMAG and Montanuniversität Leoben. The Christian Doppler Research Association (CDG) enables companies like AMAG to benefit directly from fundamental research. The aim is to use modern material characterization methods to better understand and control the impact of microstructural components in aluminium alloys. Figure 1: New scanning electron microscopy at the CMI Improving recycling and resource efficiency is a particular focus of this work.
The new CD Laboratory will examine aluminium alloys with a high proportion of recycled aluminium along with their properties. This work targets new and sustainable approaches for production of high-performance alloys. Aluminium recycling requires a deep understanding of microstructural dynamics, in particular the formation and distribution of intermetallic phases, which are often undesirable. In some alloys, impurities such as iron, copper, zinc and silicon can provide nucleation sites for undesirable phases, which can impair the alloy’s mechanical and technological properties. At the same time, these elements present an opportunity to create new microstructures with improved characteristics by implementing targeted process modifications. Crossover alloys, such as the AMAG CrossAlloy ®.57 - developed to market maturity by AMAG - illustrate the potential of these innovative approaches. However, they require a deep understanding of the underlying phase formation and development mechanisms.
Research focuses
The new CD Laboratory concentrates on three closely related research areas that lay the foundations for new industrial applications:
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Formability improvements:The ductility of aluminium alloys with a high recycled material content depends to a significant extent on their microstructure. The aim is to understand the interactions between precipitates and plastic deformation and control them in a targeted manner. Examinations of the distribution and morphology of dispersoids provide valuable insights, into the material’s formability, and help to make process-related adjustments.
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Scanning precession electron diffraction (SPED):This advanced method makes it possible analyze crystallographic orientation and phase distribution in the nanometer range. In turn, this facilitates detailed examination of textures and areas of tension that occur during forming. Such data is essential to predict how processing parameters will impact the characteristics of finished products and then carry out targeted product development for specific customer requests.
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Understanding and targeted adjustment of process parameters:This field of research focuses on recrystallization processes and grain structure control during thermomechanical processing. The objectives include maximizing mechanical properties, such as strength and ductility, while improving corrosion resistance. The development of stable primary phases is particularly important in this context.
The scientific approach pursued via the CD Laboratory, along with the long-term planning reliability it provides, make it possible to transfer fundamental insights to industrial processes. This not only creates competitive advantages but also promotes the development of sustainable material concepts.
AMAG invests in a stateof- the-art SEM at the CMI: Implementation in practice
Investment in a state-of-the-art scanning electron microscope (SEM) at AMAG’s CMI perfectly complements the fundamental research conducted at the CD Laboratory. The ZEISS GeminiSEM 460 allows detailed analyses of complex microstructures, in an industrial context. It throws a bridge between theoretical research and practical application by affording AMAG detailed insights into material microstructures. This enables AMAG and the research community to communicate on equal terms, transfer the results of lab-based research into practice, and swiftly verify fundamental research insights in industrial practice.
The ZEISS GeminiSEM 460 offers numerous analytical features tailored to AMAG’s individual requirements in relation to modern materials science and metallurgy:
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Mapping of dispersoids and precipitates: Providing resolution in the nanometer range, the ZEISS system can record the size, shape and distribution of dispersoids. This information is decisive for optimizing the recrystallization and forming properties of aluminium alloys.
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Analysis of non-conductive samples: New in-lens detectors provide razorsharp images, even at low acceleration voltages. This technology minimizes charging effects and is ideal for examination of non-conductive oxide layers and corrosion products.
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EBSD measurements: Electron backscatter diffraction (EBSD) provides important information on the crystallographic orientation and texture of materials. This data is essential for precise modeling of mechanical properties, formability and corrosion behavior.
However, an electron microscope is not an easy piece of equipment to operate. Implementation of the new SEM was accompanied by comprehensive training for the R&D staff and improvements to infrastructure at the Ranshofen site. Electromagnetic shielding and a high-purity purging system create an ideal measurement environment. Integrating the SEM into AMAG’s existing research landscape will make it possible to efficiently validate and refine the results produced by the CD Laboratory and other scientific partners - such as FELMI-ZFE, the Austrian Centre for Electron Microscopy and Nanoanalysis in Graz.
Synergies between the CD Laboratory and the AMAG CMI
The combination of well-founded fundamental research and state-of-the-art measurement technology at the CMI presents unique opportunities for AMAG. The CD Laboratory fosters a deep understanding of microstructural relationships, while the SEM helps to translate these insights into practicable solutions.
One example of this synergy is the development of alloys with an optimized texture. The models developed in the CD Laboratory made it possible to define specific rolling parameters, which were then tested and adapted using the SEM. This rapid, iterative approach makes it possible to control specific properties of new alloys and significantly shorten development cycles. Furthermore, the combination of these two resources enables a detailed examination of damage mechanisms. This makes it possible, for example, to analyze corrosion processes swiftly and develop corresponding countermeasures. Besides improving product quality, this also improves the reliability of materials for demanding applications.
Summary and customer benefits
By combining another CD Laboratory dedicated to aluminium research with investment in a state-of-the-art SEM, AMAG continues to set standards in industrial materials research. The close ties between scientific expertise and cutting-edge technology create an ideal platform for innovations in the aluminium industry. These projects not only enhance AMAG’s competitive position but also make a significant contribution to sustainability.
Consequently, AMAG offers numerous benefits for its customers:
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Higher product quality: Detailed microstructural analyses and optimized production processes lead to aluminium products with superior mechanical properties.
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Sustainability: Better recyclability and resource-friendly processes make products more environmentally friendly.
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Faster development: Interlinking fundamental research and practical application accelerates innovation cycles and cuts development times.
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Reliability: More stable processes and in-depth analyses of damage mechanisms increase product reliability and durability.
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Individual customization: Detailed microstructural analyses make it possible to tailor products precisely to specific requirements.
