Development of the 2006 Corvette Z06 Structural Cast Magnesium Crossmember

In situ fracture observation and fracture toughness analysis of squeeze cast AZ51–xSn magnesium alloys

“…Magnesium alloys have been recognized as lightest conventional structural alloys, which can cope with energy conservation and environmental pollution regulations, because they have excellent properties such as specific strength, elastic modulus, and absorbing capability of vibration, impact, and electric waves, together with a density of 1.74 g/cm 3 (about two-thirds of aluminum alloys) [1][2][3]. For wider applications of magnesium alloys, however, there remain problems to be solved, typical one of which is the lower strength, ductility, fracture toughness, and corrosion resistance than other light-weight alloys [4,5].…”

Applications of magnesium alloys in automotive engineering

“…The fi rst-in-industry one-piece magnesium die cast cradle for the Chevrolet Corvette Z06 weighs only 10.5 kg, and demonstrates a 35% mass savings over the aluminium cradle it replaced. 64 Aluminium tubes are presently used in high-volume cradle production such as the welded extrusion design for GM's mid-size cars and the hydroformed tubular subframe for the BMW 5 and 7 series. Tubular designs are generally more mass-effi cient than solid castings.…”

Effect of Friction Stir Processing on Microstructure and Mechanical Properties of a Cast-Magnesium–Rare Earth Alloy

“…[1][2][3] The majority of current magnesium applications lie in diecasting for the automotive industry and, during the 1990s, the percentage of total vehicle weight comprised of magnesium in automobiles more than doubled. [4] It has been shown that implementation of cast-magnesium components through the vehicle can potentially offer 100 kg of weight reduction per automobile.…”

“…[4] It has been shown that implementation of cast-magnesium components through the vehicle can potentially offer 100 kg of weight reduction per automobile. [1,[5][6][7] In the aircraft industry, in which the cost of weight savings is 100 to 1000 times more than in the automotive industry, low strength and poor ductility are the primary factors that inhibit the more widespread application of magnesium components. [2] Friction stir processing (FSP) (Figure 1) has been demonstrated as a viable process for increasing the strength of castings by reducing intermetallic particle size, grain size, and elimination of porosity through forging pressure, due to the combined influence of the tool tilt angle and shoulder diameter.…”