Development and application of magnesium alloy parts for automotive OEMs: A review

1. Overview:

• Title: Development and application of magnesium alloy parts for automotive OEMs: A review
• Authors: Bo Liu, Jian Yang, Xiaoyu Zhang, Qin Yang, Jinsheng Zhang, Xiaoqing Li
• Publication Year: 2023
• Publishing Journal/Academic Society: Journal of Magnesium and Alloys
• Keywords: Magnesium alloy; Original equipment manufacturer; Automotive application; Development process.

2. Research Background:

• Social/Academic Context of the Research Topic:
  China is actively pursuing "energy conservation and emission reduction" and "dual carbon" strategies. Magnesium (Mg) alloy, being China's most resource-advantaged light metal, is increasingly used in automotive, rail, aerospace, medical, and electronics sectors. Extensive research on Mg alloy preparation, properties, and processes has been conducted by institutions like Chongqing University, Shanghai Jiaotong University, and Australian National University. Over the past two decades, Mg alloy usage in the automotive industry has grown.
• Limitations of Existing Research:
  Despite the increasing use, there's a scarcity of reports detailing the design and development of Mg alloy parts specifically for automobiles. Information on the complete development process and performance requirements for these parts is limited.
• Necessity of the Research:
  This review addresses the need to summarize application models and typical part examples of Mg alloy in vehicles, focusing on the four main systems: body, chassis, powertrain, and interior/exterior. It aims to introduce the development logic for reliable die-cast Mg alloy parts for Original Equipment Manufacturers (OEMs). The goal is to share methods, processes, and key considerations for automotive OEMs in developing Mg alloy parts, thereby boosting confidence and motivation for wider adoption in the automotive field. Finally, the paper aims to identify and discuss the challenges facing Mg alloy materials and potential solutions.

3. Research Purpose and Research Questions:

• Research Purpose:
  The primary purpose of this review is to summarize the historical progression and recent advancements in the development of various Mg alloy series for automotive components. A critical analysis of existing literature is provided. Crucially, the paper aims to elucidate the entire process development technology route for die casting Mg alloy through real-world production cases. This is intended to enhance OEM confidence in developing new Mg parts and is deemed valuable for companies and manufacturers engaged in automotive lightweighting research. Furthermore, the review discusses the challenges facing Mg alloy materials in the context of national policies, environmental protection, energy saving, and consumer demands, and offers a future outlook.
• Key Research Questions:
  The research implicitly addresses questions such as:
  • What are the typical applications and models of Mg alloy parts within the four major automotive systems?
  • What is the step-by-step development process for creating reliable die-cast Mg alloy components for automotive OEMs?
  • What are the primary obstacles hindering the broader application of Mg alloys in the automotive sector?
• Research Hypotheses:
  The underlying hypothesis is that by providing a comprehensive review of Mg alloy applications, coupled with detailed OEM case studies illustrating successful development processes, the review can significantly increase OEM confidence and drive greater adoption of Mg alloys in automotive manufacturing.

4. Research Methodology:

• Research Design:
  This study employs a review-based research design, synthesizing information from existing literature and real-world case studies from automotive OEMs.
• Data Collection Method:
  The research relies on a comprehensive literature review of academic publications and industry reports related to magnesium alloys in automotive applications. It also incorporates case studies of actual OEM applications to illustrate the development process.
• Analysis Method:
  The analysis involves summarizing and critically analyzing existing literature. Case study analysis is used to understand the practical application and development process of Mg alloy parts in automotive manufacturing.
• Research Subjects and Scope:
  The scope of the review encompasses the application of different Mg alloy series in automotive components. It is structured around the four major vehicle systems: body, chassis, powertrain, and interior/exterior trim. The research specifically focuses on die casting as the primary manufacturing process and examines OEM case studies to detail the development technology route.

5. Main Research Results:

• Key Research Results:
  The review successfully summarized application models and typical part examples of Mg alloy across the four major vehicle systems. Two OEM case studies were presented to illustrate the development logic for reliable die-cast Mg alloy components. The paper also identified and categorized the multiple challenges currently hindering the wider adoption of Mg alloys in the automotive industry and discussed potential solutions.
• Statistical/Qualitative Analysis Results:
  The paper presents quantitative data in the form of tables and figures, including:
  • Table 1: "Comparison of mechanical properties of Mg alloys." This table provides density, specific heat, thermal conductivity, melting temperature, tensile strength, yield limit, elongation rate, elastic modulus, and Brinell hardness for Mg, AZ91, AM50, AS41, AE42, and AISI8Cu3 alloys.
  • Table 2: "Application areas of Mg alloy series in car body." This table lists Mg alloy series (AZ, AM, AS, AE, AXE and AJ), their performance advantages, specific classifications (e.g., AZ91D, AM60B), applications (e.g., central control bracket, seat frame), and die casting processes.
  • Table 3: "Examples of Mg front-end carriers and front upper components of some models." This table details vehicle type, period, weight/kg, and provides images of parts and vehicle types for Jaguar XJ, Jaguar XF, Benz AMG GT, Lincoln MKT, Tesla Model S, NIO ES8, Range Rover, Porsche Panamera G2, and Changan ENDO EV460.
  • Table 4: "Some cases of typical Mg CCB in automotive applications." This table lists vehicle type, weight/kg, CCB pictures, and vehicle type pictures for Rongwei 550, Ford Explorer, Dodge Caliber, LandRover LWB 5.0, LandRover LR3, ARCFOX-1(C11CB), Mercedes-Benz M-Class, Mini Cooper, Mercedes-Benz E-Class, and Voyah FREE.
  • Table 5: "Strength and modal analysis results." This table presents results for various front cover lock stiffness, load limit, ultimate pull strength, strength, radiator system module mounting point stiffness, headlight bracket stiffness, modal analysis, and acceleration shock tests, indicating whether results are qualified or not.
  • Table 6: "Mold flow analysis parameter setting." This table shows material temperature, mold temperature, pressure chamber length, material cake thickness, filling rate, critical speed, and high speed for three rounds of mold flow analysis.
  • Weight reduction percentages are mentioned for specific parts, such as "43% less" for Aston Martin DB9 side door parts and "50%" weight reduction for Chrysler Pacifica tailgate.
• Data Interpretation:
  The data presented and analyzed throughout the review consistently indicates that Mg alloys offer significant lightweighting potential in automotive applications. OEM case studies demonstrate the feasibility and benefits of using die-cast Mg alloy parts. However, the challenges related to cost, corrosion, and technological maturity remain significant hurdles to overcome for broader adoption.
• Figure Name List:
  • Fig. 1. Mg alloy in the development of automotive parts of the historical process.
  • Fig. 2. Development and application of Mg alloys in car doors.
  • Fig. 3. Development and application of Mg alloys in front-end carrier and front upper component.
  • Fig. 4. Development and application of Mg alloy on roof, hood, and trunk lid.
  • Fig. 5. The development and application of Mg alloy in the wheel.
  • Fig. 6. The development and application of Mg alloy in the steering wheel.
  • Fig. 7. The development and application of Mg alloy in subframe.
  • Fig. 8. Mg alloy in powertrain applications.
  • Fig. 9. Development and application of Mg alloy in oil pan.
  • Fig. 10. Application of Mg alloy on seat frame.
  • Fig. 11. Several applications of Mg alloy CCB.
  • Fig. 12. Several applications of Mg alloy center bracket.
  • Fig. 13. Some other Mg alloy parts for automobiles.
  • Fig. 14. MASF full process analysis process and results.
  • Fig. 15. MAFC full process analysis process and results.
  • Fig. 16. MASF detailed development process.
  • Fig. 17. MAFC detailed development process.
  • Fig. 18. Mg alloy corrosion protection solutions.

6. Conclusion and Discussion:

• Summary of Main Results:
  The review concludes that Magnesium alloy has established itself as a valuable engineering material in the automotive industry due to its advantageous properties. The paper highlighted the development technology route for die casting Mg alloy through OEM production cases. It demonstrated the extensive range of Mg alloy applications in vehicles, aiming to boost OEM confidence in utilizing these materials for new component designs. The application of Mg alloy adheres to the principle of "right material in the right place," leveraging its light density and good fluidity while mitigating drawbacks like lower strength and corrosion susceptibility. The review identifies AM50/60 and AZ91D series Mg alloys as mainstream materials, with die casting being the most common molding process. Mg alloys are typically used in skeleton or bracket forms, rather than high load-bearing beam structures, and are applied in environments less prone to galvanic corrosion. Structural design and optimization are crucial for cost reduction.
• Academic Significance of the Research:
  This review provides a comprehensive and up-to-date overview of Mg alloy applications in the automotive sector. It offers valuable academic insights into the current state of research and development, serving as a reference point for future studies and a consolidated resource for researchers in the field.
• Practical Implications:
  The review has significant practical implications for automotive OEMs. By showcasing successful OEM case studies and detailing the development process, it aims to enhance OEM confidence in adopting Mg alloys for new part development. It provides a practical reference for developing Mg alloy components and highlights key challenges and opportunities for future innovation in automotive lightweighting.
• Limitations of the Research:
  The review's scope is primarily focused on die casting processes and OEM case studies. It may not comprehensively cover all possible Mg alloy applications in automobiles or explore other manufacturing techniques in detail.

7. Future Follow-up Research:

• Directions for Follow-up Research:
  The paper suggests future research should explore:
  • Mg alloy additive manufacturing technologies.
  • Hydrogen storage applications of Mg alloys.
  • Development of a comprehensive Mg alloy material database and performance evaluation system.
  • Addressing process and cost optimization for Mg alloy manufacturing.
  • Overcoming technological innovation gaps and industrial structure contradictions.
• Areas Requiring Further Exploration:
  Future research should focus on:
  • Developing novel Mg alloy structures and technologies to achieve further weight reduction in vehicles.
  • Promoting green power electrolytic Mg technology for sustainable and recyclable Mg production.
  • Strengthening collaboration between universities, governments, and research institutions to address global challenges in Mg alloy development and application.

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9. Copyright:

• This material is Bo Liu, Jian Yang, Xiaoyu Zhang, Qin Yang, Jinsheng Zhang, Xiaoqing Li's paper: Based on Development and application of magnesium alloy parts for automotive OEMs: A review.
• Paper Source: https://doi.org/10.1016/j.jma.2022.12.015

This material was summarized based on the above paper, and unauthorized use for commercial purposes is prohibited.
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