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

This introduction paper is based on the paper "Applications of High-Pressure Die-Casting (HPDC) Magnesium Alloys in Industry" published by "IntechOpen".

1. Overview:

• Title: Applications of High-Pressure Die-Casting (HPDC) Magnesium Alloys in Industry
• Author: Sophia Fan, Xu Wang, Gerry Gang Wang and Jonathan P. Weiler
• Year of publication: 2023 (Based on copyright notice in the paper)
• Journal/academic society of publication: IntechOpen (Chapter in the book "Magnesium Alloys – Processing, Potential and Applications")
• Keywords: high pressure die cast (HPDC), magnesium alloy, castability, automotive, aerospace, lightweighting

2. Abstract:

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.

3. Introduction:

There is an increasing need for vehicle lightweighting driven by emissions and fuel economy legislation. Magnesium alloys offer significant advantages due to their low density (1.74 g/cm³), excellent specific strength, and superior castability, particularly using the high-pressure die casting (HPDC) process (Figure 1). HPDC allows for the efficient, high-volume production of complex, thin-walled, near-net-shape components with fine microstructures and high strength (Figure 2). While standard magnesium alloys have temperature limitations (around 150°C), alloys with improved heat, creep, and corrosion resistance have been developed. Furthermore, advancements in increasing thermal conductivity and improving flammability resistance are expanding potential applications into electric vehicles (EVs) and aerospace. This chapter reviews historical, current, and potential future applications of HPDC magnesium alloys in the automotive and aerospace sectors.

4. Summary of the study:

Background of the research topic:

The automotive and aerospace industries face increasing pressure to reduce vehicle weight for improved fuel/energy efficiency and performance (lightweighting). Magnesium alloys are attractive candidates due to their low density. The transition from internal combustion engine (ICE) vehicles to electric vehicles (EVs) creates new demands and opportunities for lightweight materials, particularly those with specific thermal properties. Aerospace applications also demand lightweighting but have strict flammability requirements.

Status of previous research:

HPDC magnesium alloys (like AM50, AM60, AZ91, AE44) have been successfully used for decades in various automotive applications in ICE vehicles, including interior components (instrument panels, seat frames, steering wheels), body structures (radiator supports, liftgate inners, door inners), powertrain parts (oil conduit modules, gearbox housings, transfer cases), and chassis components (engine cradles, subframes). Research has focused on improving properties like corrosion resistance, creep resistance, thermal conductivity, and flammability through alloying (e.g., RE elements, Ca).

Purpose of the study:

This chapter aims to review the applications of HPDC magnesium alloys in both historical and potential automotive (ICE and EV) and aerospace industries. It seeks to provide an overall understanding of successful examples and the ongoing development status, highlighting the potential for future growth in these sectors.

Core study:

The study reviews specific applications of HPDC magnesium alloys across different vehicle systems:

• Interior: Instrument panels (IP)/cross-car beams (CCB), seat frames, steering wheels, display brackets, center consoles, rear support brackets (RSB). Examples include evolution of JLR CCBs (Figure 4), various seatbacks (Figure 5), and other interior parts (Figure 6, Figure 7).
• Body: Roof frames, magnesium radiator supports (MRS) (Figure 8), front of dash (FOD), spare tire carriers (STC) (Figure 9), liftgate/hatchback inners, side door inners.
• Powertrain: Engine front covers, oil conduit modules, gearbox housings, transfer/transmission cases (Figure 10). Use of AE44 and AZ91D is noted.
• Chassis: Engine cradles, subframes, wheels (though primarily forged). Corrosion and porosity are key concerns.
• Other Automotive: Strut tower braces (Figure 11).
• Current EV Applications: Transferability of ICE applications (e.g., CCB, front-end carrier, door frames). EV-specific applications like onboard charger housings (Figure 12a) and potential battery trays (Figure 12b). Focus on thermal conductivity (Figure 13) and development of alloys (e.g., DSM-1, Mg-Al-Zn-RE-Ca, Mg-RE-Zn, Mg-La-Al-Mn) with improved thermal properties and castability, considering RE solubility (Figure 14).
• Aerospace Applications: Historical use (e.g., F-80C, B-36, TU-95MS) and recent re-introduction efforts driven by lightweighting needs and improved flammability resistance. Discussion of flammability standards (FAA Chapter 25) and the role of alloying elements (Ca, RE) in improving resistance (Figure 15). Development of alloys like WE43 and Ca-containing alloys (e.g., ZACE05613, AMXS6020) balancing flammability, castability, and cost.

5. Research Methodology

Research Design:

This study is a comprehensive review paper. It synthesizes information from published literature, conference proceedings, patents, and industry case studies.

Data Collection and Analysis Methods:

Data was collected from cited references [1-152], including academic papers, technical reports, industry publications, and patents. The analysis involves summarizing historical and current applications, comparing the properties and performance of different magnesium alloys (e.g., mechanical properties, corrosion, thermal conductivity, flammability), identifying trends in alloy development and application requirements (especially for EV and aerospace), and discussing the advantages and challenges of using HPDC magnesium alloys.

Research Topics and Scope:

The research focuses on the application of high-pressure die-cast (HPDC) magnesium alloys. The scope covers:

• Traditional applications in internal combustion engine (ICE) vehicles (interior, body, powertrain, chassis).
• Current and potential applications in electric vehicles (EVs), including battery-related components.
• Historical and potential applications in the aerospace industry.
• Key magnesium alloys used (AM50, AM60, AZ91, AE44, WE43, and newer developmental alloys).
• Relevant material properties: mechanical strength, ductility, castability, corrosion resistance, thermal conductivity, flammability resistance.
• The role of the HPDC process.

6. Key Results:

Key Results:

• HPDC magnesium alloys (AM50, AM60, AZ91, AE44) have been widely adopted in the automotive industry for decades due to lightweighting potential, good specific strength, and excellent castability via HPDC, enabling complex part integration.
• Key traditional applications include instrument panels, cross-car beams, seat frames, steering wheels, radiator supports, spare tire carriers, liftgate inners, door inners, powertrain casings, and chassis components like engine cradles.
• Many structural applications developed for ICE vehicles are directly transferable to EV architectures.
• EVs introduce new requirements, particularly high thermal conductivity for battery management systems. Research is ongoing to develop HPDC alloys (e.g., containing low-solubility RE elements like La, Ce) with improved thermal conductivity while maintaining good castability and mechanical properties.
• Aerospace applications, historically limited by corrosion and flammability concerns, show renewed potential due to advancements in alloys with improved flammability resistance (e.g., WE43, Ca-containing alloys) meeting FAA standards. Cost-effective, castable solutions (especially Ca-alloying) are a major focus.
• The HPDC process is crucial for manufacturing complex, thin-walled magnesium components efficiently for high-volume production.
• Challenges remain, including managing corrosion (especially galvanic), improving castability of some new alloys, controlling porosity in critical applications, and cost competitiveness.
• Novel alloy systems are being developed to combine excellent mechanical properties with application-specific needs like high thermal conductivity or flammability resistance.

Figure 2. Comparison of the yield strength of AZ91 fabricated by four different processes [22, 25].

Figure 3. Mechanical and corrosion properties of conventional HPDC magnesium alloys: (a) mechanical properties [25–27] and (b) salt spray test for 1000 hours conducted by Meridian lightweight technologies.

Figure 4. Evolution of jaguar land rover (JLR) cross car beams (CCB): (a) jaguar S-type 1963 initial design (1998); (b) first-generation magnesium CCB (2002 ~ 2007 jaguar S-type X202); (c) second-generation magnesium CCB (2008-2015 jaguar XF X250) and (d) third-generation magnesium CCB (2015-present XF X260) [28].

Figure 5. Images showing backseat applications: (a) 2014 Chevrolet corvette seatback (courtesy of GM); (b) 2015 Mercedes-Benz SLK seatback [37] (courtesy of GF casting solutions) and (c) 2014 BMW i3 seatback [38] (courtesy of BASF).

Figure 6. Images showing interior applications of HPDC magnesium alloys: (a) AZ91D automotive audio amplifier cast by Twin City die casting company [44]; (b) AM60 display bracket on 2021 ford explorer; (c) AM60 steering column cast by Meridian lightweight technologies; (d) AM50 center console on Audi A8 and (e) AM60 center stack on JLR defender [45] (courtesy of GF casting solutions).

Figure 7. AM50 left hand (LH) and right hand (RH) rear support brackets on 2022 Mercedes-AMG SL roadster cast by Meridian lightweight technologies [46].

Figure 8. Evolution of ford F-150 AM50A magnesium radiator support (MRS): (a) 2004 model; (b) 2009 model, (c) and (d) 2017 model before and after coating.

Figure 9. Evolution of jeep wrangler spare tire carrier (STC): (a) first generation on 1996 ~ 2006 model; (b) second generation on 2007 ~ 2018 model and (c) third generation on 2018 ~ present model.

Figure 10. Powertrain applications of HPDC magnesium alloys: (a) AE44 oil conduit module on Porsche Panamera [48] (courtesy of GF casting solutions) and (b) AZ91 gearbox on Volkswagen golf and Passat [45] (courtesy of GF casting solutions); (c) AZ91 transfer case on ford F-150 and (d) AZ91 transmission case prototype made by Meridian lightweight technologies.

Figure 11. Evolution of ford mustang GT strut tower mount: (top) steel stamping and aluminum extrusion strut tower mount and (bottom) HPDC magnesium strut tower brace manufactured by Meridian lightweight technologies.

Figure 12. Battery-related application of magnesium alloys: (a) HPDC AZ91D battery charger housing manufactured by Meridian lightweight technologies [89] and (b) prototyped battery tray [92] (courtesy of Fusium).

Figure 13. Influence of aluminum content on thermal conductivity of magnesium alloys: Comparison results from PANDAT simulation and tests on Mg-Al and Mg-Al-RE alloys.

Figure 14. Solubility of selected RE elements in magnesium [107, 108, 113, 114].

Figure 15. Influence of alloying on mass loss of magnesium alloys tested as per FAA chapter 25 by Meridian lightweight technologies.

Figure Name List:

• Figure 1. Schematic diagram showing high pressure die casting (HPDC) process.
• Figure 2. Comparison of the yield strength of AZ91 fabricated by four different processes [22, 25].
• Figure 3. Mechanical and corrosion properties of conventional HPDC magnesium alloys: (a) mechanical properties [25–27] and (b) salt spray test for 1000 hours conducted by Meridian lightweight technologies.
• Figure 4. Evolution of jaguar land rover (JLR) cross car beams (CCB): (a) jaguar S-type 1963 initial design (1998); (b) first-generation magnesium CCB (2002 ~ 2007 jaguar S-type X202); (c) second-generation magnesium CCB (2008-2015 jaguar XF X250) and (d) third-generation magnesium CCB (2015-present XF X260) [28].
• Figure 5. Images showing backseat applications: (a) 2014 Chevrolet corvette seatback (courtesy of GM); (b) 2015 Mercedes-Benz SLK seatback [37] (courtesy of GF casting solutions) and (c) 2014 BMW i3 seatback [38] (courtesy of BASF).
• Figure 6. Images showing interior applications of HPDC magnesium alloys: (a) AZ91D automotive audio amplifier cast by Twin City die casting company [44]; (b) AM60 display bracket on 2021 ford explorer; (c) AM60 steering column cast by Meridian lightweight technologies; (d) AM50 center console on Audi A8 and (e) AM60 center stack on JLR defender [45] (courtesy of GF casting solutions).
• Figure 7. AM50 left hand (LH) and right hand (RH) rear support brackets on 2022 Mercedes-AMG SL roadster cast by Meridian lightweight technologies [46].
• Figure 8. Evolution of ford F-150 AM50A magnesium radiator support (MRS): (a) 2004 model; (b) 2009 model, (c) and (d) 2017 model before and after coating.
• Figure 9. Evolution of jeep wrangler spare tire carrier (STC): (a) first generation on 1996 ~ 2006 model; (b) second generation on 2007 ~ 2018 model and (c) third generation on 2018 ~ present model.
• Figure 10. Powertrain applications of HPDC magnesium alloys: (a) AE44 oil conduit module on Porsche Panamera [48] (courtesy of GF casting solutions) and (b) AZ91 gearbox on Volkswagen golf and Passat [45] (courtesy of GF casting solutions); (c) AZ91 transfer case on ford F-150 and (d) AZ91 transmission case prototype made by Meridian lightweight technologies.
• Figure 11. Evolution of ford mustang GT strut tower mount: (top) steel stamping and aluminum extrusion strut tower mount and (bottom) HPDC magnesium strut tower brace manufactured by Meridian lightweight technologies.
• Figure 12. Battery-related application of magnesium alloys: (a) HPDC AZ91D battery charger housing manufactured by Meridian lightweight technologies [89] and (b) prototyped battery tray [92] (courtesy of Fusium).
• Figure 13. Influence of aluminum content on thermal conductivity of magnesium alloys: Comparison results from PANDAT simulation and tests on Mg-Al and Mg-Al-RE alloys.
• Figure 14. Solubility of selected RE elements in magnesium [107, 108, 113, 114].
• Figure 15. Influence of alloying on mass loss of magnesium alloys tested as per FAA chapter 25 by Meridian lightweight technologies.

7. Conclusion:

The review highlights the extensive and successful use of HPDC magnesium alloys (like AM50/AM60 for ductility, AZ91D for strength/corrosion, AE44 for elevated temperatures) in the automotive industry for interior, body, and powertrain applications, driven by lightweighting needs and the advantages of the HPDC process. Many of these structural applications are transferable to EV architectures. Furthermore, HPDC magnesium alloys show significant potential for EV-specific components like onboard charger housings and battery trays, although development is ongoing to optimize castability and thermal conductivity. The aerospace industry also presents opportunities, contingent on improving flammability resistance cost-effectively, with Ca-alloying showing promise. The continued development of novel magnesium alloys with tailored properties (e.g., good thermal conductivity, flammability resistance) combined with excellent mechanical performance suggests a strong and bright future for HPDC magnesium alloys in both automotive and aerospace industries.

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9. Copyright:

• This material is a paper by "Sophia Fan, Xu Wang, Gerry Gang Wang and Jonathan P. Weiler". Based on "Applications of High-Pressure Die-Casting (HPDC) Magnesium Alloys in Industry".
• Source of the paper: http://dx.doi.org/10.5772/intechopen.110494

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