Executive Summary : | Being the lightest and energy efficient structural material, Magnesium (Mg) has the potential in automotive and aerospace industry over steel and aluminium. The recent growth of usage of Mg in manufacturing sector results in a large quantity of Mg chip produced. Recycling of this material waste is an excellent way to reduce the net industrial wastage. This is also economically beneficial as Mg is costlier as compared to steel and aluminium. Most of the recycling of Mg is confined to solid-state processes where the Mg chips are initially cold pressed, then heated at a predetermined temperature for 20 mins to 2 hours of range and hot extruded at the temperature range of 250-550 °C with a very high extrusion ratio in the order of 10-30: 1 or even more. Even though the above mentioned manufacturing processes are successful in recycling Mg chips, there are lot of \demerits in above mentioned solid state manufacturing recycling processes; such as (i) the existing solid state manufacturing route is complex, time consuming and require large energy consumption, (ii) Mg is very prone to oxidation which leads to formation of a very strong passive layer of oxidation along the surface of the Mg chips and Mg scraps. Solid state bonding is not possible with the presence of unavoidable oxide layers along the chip surface. In spite of all the precautions, trace/cluster of oxide layer/particles are often seen in the recycled products which deteriorate the end use properties/performance. Remelting based liquid state manufacturing route is the simplest, cost effective and mass scale production process of recycling and this processing route is most commonly used for recycling of Steel and other alloys. However, the process is not being used for recycling of Mg chips /scraps due to the inherent oxidation tendency of Mg alloys. The presence of existing oxide layers in the Mg chips significantly increases the melting temperature of Mg alloy chips and hence higher temperature is required for remelting of Mg alloy chips. Being an oxidizing material, the oxidation kinetics of Mg increases with increase in temperature. Therefore, remelting of Mg chips causes significant fraction of further oxide layer formation. The present work is focused to establish two novel Microwave based Mg recycling technologies for transforming Mg chips and scraps into high performance sheets. The 1st proposed novel manufacturing route is a solid state dynamic loaded microwave manufacturing technology to recycle Mg chips into solid blocks. The 2nd promised technology is to establish a remelting based liquid state microwave-ultrasonic route to recycle Mg chips/scraps into solid blocks. The secondary differential speed rolling will be imparted to the solid blocks obtained from both of the processes in order to transform them into high performance fine/ultrafine grained sheets. Such fine/ultrafine grained Mg alloys often exhibits high strength, high ductilityand high strain rate superplasticity |