Energy-Aware Thermomechanical Processing and Corrosion Response of Rare-Earth Magnesium Sheets: A Perspective for Sustainable Manufacturing

Abstract

Rare-earth (RE)-containing magnesium sheet alloys are promising for lightweight structures because they can reduce anisotropy and improve warm formability. Their industrial relevance, however, should be assessed not only through mechanical performance, but also through process-energy demand, corrosion durability, and critical-raw-material considerations. This perspective examines Mg–Zn–RE sheets, with ZE10A as an anchor case, to connect three issues that are often treated separately: low-temperature warm-forming windows, deformation-induced microstructural stability, and corrosion-film kinetics. Current evidence indicates that in the approximately 250–300 ℃ range, recovery and incipient dynamic recrystallization may improve formability while limiting major grain or phase evolution. Under these recovery-dominated conditions, we propose, as a working hypothesis, that the influence of thermomechanical history on corrosion is mediated primarily by defect architecture, near-surface heterogeneity, and the formation and breakdown kinetics of dynamic, non-passivating films, rather than by extensive precipitation or classical microgalvanic changes. A screening-level discussion of process-energy demand, together with a database-based comparison of the embodied energy and carbon footprint of selected rare-earth elements, is used to frame responsible alloy and processing decisions without claiming a full life-cycle assessment. The perspective concludes with a research roadmap integrating history-faithful forming tests, correlative microstructure mapping, time-resolved electrochemistry, and transparent sustainability assumptions to support predictive manufacturing design rules for Mg–RE sheets.

Keywords

Magnesium sheet / Rare-earth alloy / Warm forming / Sustainable manufacturing / Dynamic recrystallization / Corrosion film / Neodymium criticality / Energy screening

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