Thin-walled and large-sized magnesium alloy die castings for passenger car cockpit: Application, materials, and manufacture

1. Overview:

  • Title: Thin-walled and large-sized magnesium alloy die castings for passenger car cockpit: Application, materials, and manufacture
  • Authors: Lei Zhan, Yu-meng Sun, Yang Song, Chun-hua Kong, **Kai Ma, Bai-xin Dong, Hong-yu Yang, Shi-li Shu, and *Feng Qiu
  • Publication Year: 2024
  • Journal/Conference: CHINA FOUNDRY Vol. 21 No. 5 September 2024
  • Keywords: Mg alloys; thin wall; large size; automotive part; die casting

2. Research Background:

  • Social/Academic Context of Research Topic: In order to effectively reduce energy consumption and increase range mile, new energy vehicles represented by Tesla have greatly aroused the application of integrated magnesium (Mg) alloy die casting technology in automobiles. Previously, the application of Mg alloys in automobiles, especially in automotive cockpit components, is quite extensive, while it has almost disappeared for a period of time due to its relatively high cost, causing a certain degree of information loss in the application technology of Mg alloy parts in automobiles. The rapid development of automotive technology has led to a higher requirement for the automotive components compared with those traditional one. Therefore, whatever the components themselves, or the Mg alloy materials and die casting process have to face an increasing challenge, needing to be upgraded. In addition, owing to its high integration characteristics, the application of Mg alloy die casting technology in large-sized and thin-walled automotive parts has inherent advantages and needs to be expanded urgently. Indeed, it necessitates exploring advance Mg alloys and new product structures and optimizing die casting processes.
  • Limitations of Existing Research: While the paper doesn't explicitly state limitations of existing research, it implies a gap in current knowledge by mentioning "causing a certain degree of information loss in the application technology of Mg alloy parts in automobiles" in the introduction.
  • Necessity of Research: This article summarizes and analyzes the development status of thin-walled and large-sized die casting Mg alloy parts in passenger car cockpit and corresponding material selection methods, die casting processes as well as mold design techniques. Furthermore, this work will aid researchers in establishing a comprehensive understanding of the manufacture of thin-walled and large-sized die casting Mg alloy parts in automobile cockpit. It will also assist them in developing new Mg alloys with improved comprehensive performance and new processes to meet the high requirements for die casting automotive components.

3. Research Objectives and Research Questions:

  • Research Objective: The objective of this research is to summarize and analyze the development status of thin-walled and large-sized die casting Mg alloy parts in passenger car cockpits, along with corresponding material selection methods, die casting processes, and mold design techniques. Ultimately, it aims to provide researchers with a comprehensive understanding of the field and support the development of new Mg alloys and processes that meet the high-performance die casting requirements for automotive components in the future.
  • Core Research Questions: While the paper doesn't explicitly list research questions, based on the research objectives, we can infer the following core questions:
    • Which components in passenger car cockpits are suitable for thin-walled and large-sized Mg alloy die casting, and what is the application status of each component?
    • What material properties are required for thin-walled and large-sized Mg alloy die casting parts, and which commercial Mg alloys are suitable?
    • What are the appropriate die casting processes and conditions for manufacturing thin-walled and large-sized Mg alloy die casting parts?
    • What are the mold design considerations for ensuring the quality of thin-walled and large-sized Mg alloy die casting parts?
  • Research Hypothesis: There is no explicit research hypothesis stated in the paper.

4. Research Methodology

  • Research Design: This research adopts a review article format rather than a specific research design. It comprehensively analyzes existing literature and research data to analyze the technological trends and key issues of thin-walled and large-sized Mg alloy die casting parts.
  • Data Collection Methods: The research primarily collects and analyzes publicly available literature information, including academic papers, technical reports, and industry data. It does not involve specific experimental data collection or surveys.
  • Analysis Methods: Based on the collected literature information, the research conducts technology trend analysis, material property comparison analysis, process technology analysis, and mold design technology analysis. The focus is on analyzing, comparing, and summarizing technical content rather than quantitative data analysis.
  • Research Subjects and Scope: The research focuses on thin-walled and large-sized Mg alloy die casting parts among passenger car cockpit components. Specifically, it includes components such as seat frames, CCB (cross car beam), center console frames, and door inners. The research scope covers material selection, die casting processes, mold design, and surface treatment technologies.

5. Key Research Findings:

  • Core Findings:
    • Thin-walled and large-sized Mg alloy die casting parts are an effective solution for lightweighting passenger car cockpits, and their importance is increasing, especially in the field of new energy vehicles.
    • Among passenger car cockpit components, seat frames, CCBs, and center console frames have relatively mature Mg alloy die casting technology applications, and the application scope is expanding to door inner and rear tailgate components.
    • AM series alloys (AM50, AM60) are currently the most widely used materials for automotive cockpit die casting parts, but there is a growing demand for Mg alloys with higher mechanical properties. Mg-RE series alloys have excellent high-temperature properties, but their high cost is a disadvantage.
    • Die casting process conditions and mold design have a significant impact on the quality of thin-walled and large-sized Mg alloy die casting parts, and optimized design and process control are crucial. In particular, thin-walled parts are prone to defects, requiring meticulous process management.
    • Vacuum-assisted HPDC is an effective method to reduce porosity in Mg alloy die casting parts and improve mechanical properties.
    • Surface treatment is essential to ensure the corrosion resistance of Mg alloy parts, and various surface treatment technologies (chemical conversion coating, anodizing, etc.) can be applied.
  • Statistical/Qualitative Analysis Results:
    • Comparative analysis of material properties (YS, UTS, Elongation) of various commercial Mg alloys (AZ91, AM50, AM60, WE43, WE54) is performed to present the advantages and disadvantages of each alloy and their application fields (Table 1, 2, 3).
    • Analysis of the influence of die casting process variables (injection speed, mold temperature, pressure, etc.) on part quality, emphasizing the importance of setting optimal process conditions.
    • Analysis of the influence of mold design elements (die cavity, gating system, runner, gate, rib, etc.) on part formability and quality, and presentation of optimal mold design solutions.
    • Comparative analysis of pore distribution and mechanical properties of LA42 alloy castings between vacuum die casting and conventional HPDC to demonstrate the effectiveness of vacuum die casting (Fig. 11).
  • Data Interpretation:
    • Mg alloys have excellent properties such as lightweightness, rigidity, and strength, contributing to the lightweighting of automotive parts, but also have disadvantages such as low elongation, corrosion resistance, and high cost.
    • Successful manufacturing of thin-walled and large-sized Mg alloy die casting parts requires comprehensive consideration of all factors, including material selection, process optimization, mold design, and surface treatment.
    • It is expected that the application range of Mg alloy die casting parts in automobiles can be further expanded through technology development and cost reduction.
  • Figure Name List:
    • Fig. 1: First high-volume one-piece die cast Mg alloy CCB
    • Fig. 2: Exploded view of the center console with conventional structure
    • Fig. 3: Application of Mg alloys center console frame in automobile
    • Fig. 4: Traditional seat back frame structure
    • Fig. 5: Traditional seat cushion frame structure
    • Fig. 6: Seat frame consisting of 5 Mg die casting parts
    • Fig. 7: Images showing Mg alloy seat frame applications in 2015 Mercedes-Benz SLK seat
    • Fig. 8: Typical Mg alloy seat back frame
    • Fig. 9: Prototype of Mg alloy door inner die casting
    • Fig. 10: Schematic of a cold chamber die-casting machine
    • Fig. 11: Comparison of the LA42 alloy casting of HPDC and vacuum-assisted HPDC
    • Fig. 12: Typical redundant materials on the part of Mg alloy die casting
    • Fig. 13: Surface treatment process flow for Mg alloy die casting parts
    • Fig. 14: Surface morphologies of AZ31 Mg alloy after anodizing at 3 V (a), 10 V (b), 20 V (c), 70 V (d), 80 V (e), and 100 V (f)
    • Fig. 15: Typical surface defects of thin wall Mg alloy parts
    • Fig. 16: Suggestions for the design of the die casting parts with uniform wall thickness
    • Fig. 17: Some suggestions about how to layout the ribs on the die casting parts
    • Fig. 18: Gating system of Mg alloy die castings
    • Fig. 19: Different runner designs of Mg alloy die casting dies and their impact on filling process
    • Fig. 20: Different gate system designs of Mg alloy die casting seat frame
Fig. 1: First high-volume one-piece die cast Mg alloy CCB: (a) 3D data [18]; (b) CCB for GMC Savana and Chevrolet Express; (c) CCB for Buick LaCrosse [19]
Fig. 1: First high-volume one-piece die cast Mg alloy CCB: (a) 3D data [18]; (b) CCB for GMC Savana and Chevrolet Express; (c) CCB for Buick LaCrosse [19]
Fig. 2: Exploded view of the center console with conventional structure: (a) the shell itself is outer skin; (b) with a structural component inside [21]
Fig. 2: Exploded view of the center console with conventional structure: (a) the shell itself is outer skin; (b) with a structural component inside [21]
Fig. 3: Application of Mg alloys center console frame in automobile: (a) Porsche [6]; (b) Volvo; (c) Hongqi
Fig. 3: Application of Mg alloys center console frame in automobile: (a) Porsche [6]; (b) Volvo; (c) Hongqi
Fig. 4: Traditional seat back frame structure: (a) main material; (b) corresponding weight for each part
Fig. 4: Traditional seat back frame structure: (a) main material; (b) corresponding weight for each part
Fig. 5: Traditional seat cushion frame structure: (a) main material; (b) corresponding weight for each part
Fig. 5: Traditional seat cushion frame structure: (a) main material; (b) corresponding weight for each part
Fig. 6: Seat frame consisting of 5 Mg die casting parts: (a) backrest; (b) cushion; (c) assembly [11]
Fig. 6: Seat frame consisting of 5 Mg die casting parts: (a) backrest; (b) cushion; (c) assembly [11]
Fig. 10: Schematic of a cold chamber die-casting machine (a), and stages of the shot profile for die casting process showing changes of melt pressure and plunger displacement versus time (b) [91]
Fig. 10: Schematic of a cold chamber die-casting machine (a), and stages of the shot profile for die casting process showing changes of melt pressure and plunger displacement versus time (b) [91]
Fig. 17: Some suggestions about how to layout the ribs on the die casting parts [127]
Fig. 17: Some suggestions about how to layout the ribs on the die casting parts [127]
Fig. 19: Different runner designs of Mg alloy die casting dies and their impact on filling process: (a) Y shape runner; (b) T shape runner; (c) radiation shape runner; (d) tracer particles during the filling simulation of the Y shape runner; (e) tracer particles during the filling simulation of the T shape runner [125]
Fig. 19: Different runner designs of Mg alloy die casting dies and their impact on filling process: (a) Y shape runner; (b) T shape runner; (c) radiation shape runner; (d) tracer particles during the filling simulation of the Y shape runner; (e) tracer particles during the filling simulation of the T shape runner [125]
Fig. 20: Different gate system designs of Mg alloy die casting seat frame: (a) [134] and (b) [29] for backrest; (c) and (d) for cushion [25]
Fig. 20: Different gate system designs of Mg alloy die casting seat frame: (a) [134] and (b) [29] for backrest; (c) and (d) for cushion [25]

6. Conclusion and Discussion:

  • Summary of Main Findings: The popularization of new energy vehicles has greatly promoted the development of lightweight technology, and the application of Mg alloys die casting is desirable in many lightweight technologies. Due to its relatively high integration, die casting technology is more suitable for the integrating of numerous small parts to form the thin-walled and large-sized parts, making a significant effect on the components lightweight. Technically, the suitable components, selection of Mg alloy materials, die casting process, and the design of die casting molds will greatly impact the quality of the final parts. Through the related research, following conclusions could be obtained: (The conclusions are the same as in the Korean summary, already provided in section 5. Key Research Findings - Core Findings)
  • Academic Significance of Research: This study provides a comprehensive technical trend analysis of the application of thin-walled and large-sized Mg alloy die casting parts in automobile cockpits, and can contribute to setting the direction for future research and development. In particular, it enhances academic value by presenting technical challenges and solutions from various aspects such as materials, processes, and mold design.
  • Practical Implications: This study provides useful information on the application of Mg alloy die casting technology to practitioners in the field of automotive part design and manufacturing. In particular, it increases the feasibility of practical application by presenting specific guidelines for thin-walled and large-sized part design, material selection, process condition setting, and mold design.
  • Limitations of Research: This research is a review paper based on literature research, and lacks in-depth experimental verification for specific alloys or processes. In addition, analysis related to economic aspects such as cost, productivity, and recyclability is insufficient. Future research needs to address these limitations through in-depth studies.

7. Future Follow-up Research:

  • Future Follow-up Research:
    • Research on the development of low-cost and high-strength Mg-RE alloys
    • Research on improving the performance of thin-walled and large-sized Mg alloy die casting parts (strength, elongation, corrosion resistance, fatigue properties, etc.)
    • Research on die casting process optimization and elucidation of defect generation mechanisms (porosity, ESC, etc.)
    • Research on integrated design and manufacturing technology for Mg alloy die casting parts (reduction of part count, simplification of assembly process)
    • Research on recycling technology for Mg alloy die casting parts
  • Areas Requiring Further Exploration:
    • Evaluation of fatigue properties and durability of Mg alloy die casting parts
    • Evaluation of creep properties and high-temperature reliability of Mg alloy die casting parts
    • Evaluation of impact properties and safety of Mg alloy die casting parts
    • LCA (Life Cycle Assessment) analysis and development of environmentally friendly manufacturing processes for Mg alloy die casting parts

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9. Copyright:

This material is based on Feng Qiu's paper: Thin-walled and large-sized magnesium alloy die castings for passenger car cockpit: Application, materials, and manufacture.
Paper Source: https://doi.org/10.1007/s41230-024-4100-z
This material is a summarized version of the above paper, and unauthorized use for commercial purposes is prohibited.
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Thin-walled and large-sized magnesium alloy die castings for passenger car cockpit-Application, materials, and manufactureDownload
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