The Application of Magnesium Die Casting to Vehicle Closures

Blanchard, P.; Bretz, G. T.; Saravanan, S.; deVries, J.E.; Syvret, Andrew; Macdonald, A. J.; Jolley, Peter

doi:10.4271/2005-01-0338

Cited by 17 publications

(3 citation statements)

References 7 publications

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“…The uses of magnesium alloys in the automotive industry are presented in Table 14. AM50 (Mg5.0Al0.3Mn) cross car beam (Voyah Free) [349] AM50A (MgAl5Mn) central control bracket (Volvo XC60) [349] AM50A (MgAl5Mn) front-end carrier (Porsche Panamera G2) [349] AM50 (Mg5.0Al0.3Mn) side door (Aston Martin DB9) [364] AM60B (Mg-6Al-0.4Mn) cross car beam [365] AM60B (Mg-6Al-0.4Mn) seat frame [361] AM60B (Mg-6Al-0.4Mn) front-end carrier (Tesla S) [366] AM60B (Mg-6Al-0.4Mn) inside door panel [367] AM60B (Mg-6Al-0.4Mn) front-end frame [368] AM60B (Mg-6Al-0.4Mn) folding roofs (Mercedes Benz SLK) [349] AM60B (Mg-6Al-0.4Mn) body structure (Chrysler) [369] AM60B (Mg-6Al-0.4Mn) front-end carrier (Range Rover) [349,370] AS41B (Mg-4Al-0.3Mn-1Si) crankcase housing [371] AS41B (Mg-4Al-0.3Mn-1Si) transmission housing [372] AS21 (MgAl2.2Si1Mn0.3), AS41 (MgAl4.5Si1Mn0.3) transmission housing, crank case (Volkswagen) [358] AZ31 (Mg-3Al-1Zn-0.2Mn) inner panel [373] AZ31B (Mg-3Al-1Zn) upper rail (USAMP project) [354] Table 14. Cont.…”

Section: Application Of Magnesium Alloys In Car Body Componentsmentioning

confidence: 99%

Current Trends in Metallic Materials for Body Panels and Structural Members Used in the Automotive Industry

Trzepieciński,

Najm

2024

Materials

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The development of lightweight and durable materials for car body panels and load-bearing elements in the automotive industry results from the constant desire to reduce fuel consumption without reducing vehicle performance. The investigations mainly concern the use of these alloys in the automotive industry, which is characterised by mass production series. Increasing the share of lightweight metals in the entire structure is part of the effort to reduce fuel consumption and carbon dioxide emissions into the atmosphere. Taking into account environmental sustainability aspects, metal sheets are easier to recycle than composite materials. At the same time, the last decade has seen an increase in work related to the plastic forming of sheets made of non-ferrous metal alloys. This article provides an up-to-date systematic overview of the basic applications of metallic materials in the automotive industry. The article focuses on the four largest groups of metallic materials: steels, aluminium alloys, titanium alloys, and magnesium alloys. The work draws attention to the limitations in the development of individual material groups and potential development trends of materials used for car body panels and other structural components.

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Section: Application Of Magnesium Alloys In Car Body Componentsmentioning

confidence: 99%

Current Trends in Metallic Materials for Body Panels and Structural Members Used in the Automotive Industry

Trzepieciński,

Najm

2024

Materials

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“…The utilization examples of magnesium cast door inners grown in luxury vehicles are a Ford magnesium door inner prototype project [61], the 2004 Aston Martin DB9 side door inner [62], the 2017 Aston Martin Vanquish S side door inner [58] and the GM integrated side door inner panel R&D project [63]. Some of the latest body structure applications of HPDC magnesium alloys include the door inner upper beltline reinforcement on the 2020 Chevrolet Corvette [63] and a convertible roof top on the 2013 Opel Cascade Cabrio [64].…”

Section: Body Applicationsmentioning

confidence: 99%

Applications of High-Pressure Die-Casting (HPDC) Magnesium Alloys in Industry

Fan¹,

Wang²,

Wang³

et al. 2023

Magnesium Alloys - Processing, Potential and Applications

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High-pressure die-cast (HPDC) magnesium alloys have seen diverse applications in the automotive industry, primarily driven by requirements in internal combustion engine (ICE) vehicles. As the automotive industry is transitioning to an electric vehicle (EV) architecture, there is a great potential for novel applications to improve driving range efficiency. In addition, there is a trend toward larger-sized automotive die castings and an increased interest in aerospace applications due to weight reduction. In this chapter, we reviewed the traditional automotive structural applications in ICE vehicles, as well as current and potential future EV and aerospace applications of HPDC magnesium alloys. The structural applications using AM50, AM60, AZ91 and AE44 magnesium alloys in traditional vehicles can be applied to modern EVs. Additionally, magnesium alloys with varying degrees of higher thermal conductivity, improved castability, superior high temperature properties and flammability need to be developed to replace battery and aerospace in-cabin-related structural materials to meet all safety requirements. Several newly developed magnesium alloys with superior castability are also reviewed for potential automotive and aerospace applications.

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“…For example, the Corvette engine cradle [46] and the Ford F150 grill opening radiator support [47] both have large frame-like structures. Likewise, closures such as the Aston Martin DB9 door inner [48] and, recently, the rear liftgate inner of the Ford MKT [49] are structures with window openings and have large, long sections. These frame-like structures tend to have some unique features such as the melt flow lengths that exceed 2 to 3 m and areas where melt fronts meet inside the casting.…”

Section: Introductionmentioning

confidence: 99%

Using quality mapping to predict spatial variation in local properties and component performance in Mg alloy thin-walled high-pressure die castings: an ICME approach and case study

Forsmark

Zindel

Godlewski

et al. 2015

Integr Mater Manuf Innov

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This paper explores the use of quality mapping for the prediction of the spatial variation in local properties in thin-walled high-pressure die castings (HPDC) of the magnesium alloy AM60. The work investigates the role of casting parameters on local ductility and yield strength and presents a model for predicting local ductility and yield strength in a cast component. A design of experiment (DOE) was created to examine the role of various casting parameters on local properties such as ductility and yield strength. Over 1,200 tensile samples were excised from cast parts and tested. Casting simulations were also conducted for each experimental condition. Local properties were predicted, and the local property (quality map) model was compared with a prototype production component. The results of this model were used as input to a performance simulation software code to simulate the component-level behavior under two different loading conditions. In this study, the authors bypassed the traditional Integrated Computational Materials Engineering (ICME; process-microstructure-properties) approach in favor of a semi-empirical quality mapping approach to provide estimates of manufacturing sensitive local properties for use in process and component design.

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The Application of Magnesium Die Casting to Vehicle Closures

Cited by 17 publications

References 7 publications

Current Trends in Metallic Materials for Body Panels and Structural Members Used in the Automotive Industry

Current Trends in Metallic Materials for Body Panels and Structural Members Used in the Automotive Industry

Applications of High-Pressure Die-Casting (HPDC) Magnesium Alloys in Industry

Using quality mapping to predict spatial variation in local properties and component performance in Mg alloy thin-walled high-pressure die castings: an ICME approach and case study

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