産業分野における高圧ダイカスト(HPDC)マグネシウム合金の応用

本紹介論文は、「IntechOpen」によって出版された論文「Applications of High-Pressure Die-Casting (HPDC) Magnesium Alloys in Industry」に基づいています。

1. 概要:

• タイトル: Applications of High-Pressure Die-Casting (HPDC) Magnesium Alloys in Industry (産業分野における高圧ダイカスト(HPDC)マグネシウム合金の応用)
• 著者: Sophia Fan, Xu Wang, Gerry Gang Wang and Jonathan P. Weiler
• 発行年: 2023年 (論文中の著作権表示に基づく)
• 発行学術誌/学会: IntechOpen (書籍「Magnesium Alloys – Processing, Potential and Applications」内の章)
• キーワード: high pressure die cast (HPDC), magnesium alloy, castability, automotive, aerospace, lightweighting

2. 抄録:

高圧ダイカスト(HPDC)マグネシウム合金は、主に内燃機関(ICE)自動車の要件によって、自動車産業で多様な応用が見られてきました。自動車産業が電気自動車(EV)アーキテクチャに移行するにつれて、走行距離効率を改善するための新しい応用の大きな可能性があります。さらに、より大型の自動車用ダイカスト部品への傾向と、軽量化による航空宇宙用途への関心の高まりがあります。本章では、ICE自動車における従来の自動車構造用途、ならびにHPDCマグネシウム合金の現在および将来の潜在的なEVおよび航空宇宙用途をレビューしました。従来の自動車でAM50、AM60、AZ91、AE44マグネシウム合金を使用した構造用途は、現代のEVにも適用できます。加えて、より高い熱伝導率、改善された鋳造性、優れた高温特性、および難燃性を様々な程度で持つマグネシウム合金を開発する必要があり、これはバッテリーおよび航空宇宙のキャビン関連構造材料を置き換えて、すべての安全要件を満たすためです。優れた鋳造性を持ついくつかの新しく開発されたマグネシウム合金も、潜在的な自動車および航空宇宙用途のためにレビューされています。

3. 序論:

排出ガスおよび燃費規制により、車両の軽量化の必要性が高まっています。したがって、軽量化は、安全性と性能を維持しながら動力効率を向上させるための非常に重要なトピックとなっています。製品の最適化、材料置換、部品統合などのいくつかの軽量化戦略は、より高密度の構造材料をより低密度の材料に置き換えることによって推進されています。
マグネシウムとその合金は、他の自動車用金属と比較していくつかの利点があります。マグネシウムの密度は1.74 g/cm³であり、アルミニウムと鋼の両方よりも著しく低いです[1]。マグネシウム合金は、優れた比強度、優れた自動化可能性と鋳造性特性を持ち、セルフスレッディングファスナーの使用に適していることでよく知られています[2]。一般的に使用されるマグネシウム合金は150°C以上での使用には不適切かもしれませんが[3, 4]、適切な合金元素の添加により、耐熱性[5–7]および耐食性[8, 9]のマグネシウム合金が開発されています。自動車産業は、内燃機関(ICE)から電気自動車(EV)へのパワートレインアーキテクチャの移行を経験しています。マグネシウム合金の熱伝導率向上の開発は、バッテリー関連の応用をサポートしています[7]。一方、難燃性はマグネシウム合金のホットなトピックであり、関連研究は実質的な進歩を遂げており、これは航空宇宙用途にとって非常に価値があります[10–19]。上記の利点により、マグネシウム合金は自動車産業で広範に利用される最も軽量で最も人気のある構造用金属の1つとなっています。
産業界のほとんどのマグネシウム合金部品は、Figure 1に示される高圧ダイカスト(HPDC)プロセス[20–21]を通じて製造されます。HPDCプロセスは、設計と製造における魅力的な柔軟性、優れたダイ充填特性、および鋼構造に必要な二次加工削減の高い効率性を提供します。Figure 2は、いくつかの異なるプロセスで製造されたAZ91の降伏強度を比較しています[22–25]。HPDCプロセスで製造されたものの高い強度は、速い冷却速度からの著しく微細な微細構造の結果です。現代のHPDC技術により、マグネシウム合金は、大型、薄肉、複雑な形状を持つニアネットシェイプ製品として製造でき、優れた構造的および機能的性能を示し、特に大量生産のための効率的でコスト削減の方法として広く適用されています。
本章では、歴史的および潜在的な自動車および航空宇宙産業におけるHPDCマグネシウム合金の応用をレビューし、成功事例と進行中の開発状況の全体的な理解を提供します。

4. 研究の概要:

研究テーマの背景:

自動車および航空宇宙産業は、燃費/エネルギー効率と性能向上のために車両軽量化への圧力が高まっています（軽量化）。マグネシウム合金は、その低密度により魅力的な候補材料です。内燃機関(ICE)自動車から電気自動車(EV)への移行は、軽量材料、特に特定の熱特性を持つ材料に対する新たな要求と機会を生み出しています。航空宇宙用途も軽量化を要求しますが、厳格な難燃性要件があります。

先行研究の状況:

HPDCマグネシウム合金（AM50、AM60、AZ91、AE44など）は、ICE自動車の様々な用途で数十年にわたり成功裏に使用されてきました。これには、内装部品（インストルメントパネル、シートフレーム、ステアリングホイール）、ボディ構造（ラジエーターサポート、リフトゲートインナー、ドアインナー）、パワートレイン部品（オイルコンジットモジュール、ギアボックスハウジング、トランスファーケース）、シャシー部品（エンジンクレードル、サブフレーム）が含まれます。研究は、合金化（例：RE元素、Ca）を通じて、耐食性、耐クリープ性、熱伝導率、難燃性などの特性を改善することに焦点を当ててきました。

研究の目的:

本章は、歴史的および潜在的な自動車（ICEおよびEV）および航空宇宙産業におけるHPDCマグネシウム合金の応用をレビューすることを目的としています。成功事例と進行中の開発状況の全体的な理解を提供し、これらの分野における将来の成長の可能性を強調することを目指しています。

中核研究:

本研究は、さまざまな車両システムにわたるHPDCマグネシウム合金の特定の応用をレビューします：

• 内装: インストルメントパネル(IP)/クロスカービーム(CCB)、シートフレーム、ステアリングホイール、ディスプレイブラケット、センターコンソール、リアサポートブラケット(RSB)。例として、JLR CCBの進化(Figure 4)、様々なシートバック(Figure 5)、その他の内装部品(Figure 6, Figure 7)が含まれます。
• ボディ: ルーフフレーム、マグネシウムラジエーターサポート(MRS)(Figure 8)、フロントオブダッシュ(FOD)、スペアタイヤキャリア(STC)(Figure 9)、リフトゲート/ハッチバックインナー、サイドドアインナー。
• パワートレイン: エンジンフロントカバー、オイルコンジットモジュール、ギアボックスハウジング、トランスファー/トランスミッションケース(Figure 10)。AE44およびAZ91Dの使用が言及されています。
• シャシー: エンジンクレードル、サブフレーム、ホイール（主に鍛造）。腐食と気孔が主な懸念事項です。
• その他の自動車: ストラットタワーブレース(Figure 11)。
• 現在のEV応用: ICE応用の移行可能性（例：CCB、フロントエンドキャリア、ドアフレーム）。オンボードチャージャーハウジング(Figure 12a)や潜在的なバッテリートレイ(Figure 12b)などのEV特有の応用。熱伝導率(Figure 13)および改善された熱特性と鋳造性を持つ合金開発（例：DSM-1、Mg-Al-Zn-RE-Ca、Mg-RE-Zn、Mg-La-Al-Mn）に焦点を当て、RE溶解度(Figure 14)を考慮します。
• 航空宇宙応用: 歴史的な使用（例：F-80C、B-36、TU-95MS）および軽量化の必要性と改善された難燃性による最近の再導入の取り組み。難燃性基準（FAA Chapter 25）および合金元素（Ca、RE）の耐性向上における役割(Figure 15)の議論。難燃性、鋳造性、コストのバランスをとった合金（例：WE43およびCa含有合金 - ZACE05613、AMXS6020）の開発。

5. 研究方法論

研究デザイン:

本研究は包括的なレビュー論文です。公開された文献、会議議事録、特許、および業界のケーススタディからの情報を統合しています。

データ収集と分析方法:

データは引用された参考文献[1-152]から収集され、これには学術論文、技術報告書、業界出版物、特許が含まれます。分析には、歴史的および現在の応用の要約、異なるマグネシウム合金の特性と性能の比較（例：機械的特性、腐食、熱伝導率、難燃性）、合金開発と応用要件（特にEVおよび航空宇宙向け）のトレンドの特定、HPDCマグネシウム合金使用の利点と課題の議論が含まれます。

研究トピックと範囲:

本研究は高圧ダイカスト(HPDC)マグネシウム合金の応用に焦点を当てています。範囲は以下の通りです：

• 内燃機関(ICE)自動車における従来の応用（内装、ボディ、パワートレイン、シャシー）。
• バッテリー関連部品を含む電気自動車(EV)における現在および潜在的な応用。
• 航空宇宙産業における歴史的および潜在的な応用。
• 使用される主要なマグネシウム合金（AM50、AM60、AZ91、AE44、WE43、および新しい開発合金）。
• 関連する材料特性：機械的強度、延性、鋳造性、耐食性、熱伝導率、難燃性。
• HPDCプロセスの役割。

6. 主要な結果:

主要な結果:

• HPDCマグネシウム合金（AM50、AM60、AZ91、AE44）は、軽量化の可能性、良好な比強度、HPDCによる優れた鋳造性により、複雑な部品統合を可能にし、数十年にわたり自動車産業で広く採用されてきました。
• 主要な従来の応用には、インストルメントパネル、クロスカービーム、シートフレーム、ステアリングホイール、ラジエーターサポート、スペアタイヤキャリア、リフトゲートインナー、ドアインナー、パワートレインケーシング、エンジンクレードルなどのシャシー部品が含まれます。
• ICE車両用に開発された多くの構造応用は、EVアーキテクチャに直接移行可能です。
• EVは、特にバッテリー管理システムのための高い熱伝導率といった新たな要件を導入します。良好な鋳造性と機械的特性を維持しながら、改善された熱伝導率を持つHPDC合金（例：低溶解度のRE元素La、Ceを含む）を開発するための研究が進行中です。
• 歴史的に腐食と難燃性の懸念によって制限されていた航空宇宙用途は、FAA基準を満たす改善された難燃性を持つ合金（例：WE43、Ca含有合金）の進歩により、新たな可能性を示しています。費用対効果が高く、鋳造可能なソリューション（特にCa合金化）が主要な焦点です。
• HPDCプロセスは、複雑で薄肉のマグネシウム部品を大量生産のために効率的に製造するために不可欠です。
• 腐食管理（特にガルバニック腐食）、一部の新合金の鋳造性改善、重要な応用における気孔制御、コスト競争力などの課題が残っています。
• 優れた機械的特性と、高い熱伝導率や難燃性などの応用特有のニーズを組み合わせた新しい合金システムが開発されています。

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.

図の名称リスト:

• 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. 結論:

本レビューは、軽量化の必要性とHPDCプロセスの利点により、自動車産業において内装、ボディ、パワートレイン用途でHPDCマグネシウム合金（延性用のAM50/AM60、強度/耐食性用のAZ91D、高温用のAE44など）が広範かつ成功裏に使用されてきたことを強調しています。これらの構造応用の多くはEVアーキテクチャに移行可能です。さらに、HPDCマグネシウム合金は、オンボードチャージャーハウジングやバッテリートレイなどのEV特有の部品に大きな可能性を示していますが、鋳造性と熱伝導率を最適化するための開発が進行中です。航空宇宙産業も、費用対効果の高い難燃性改善（特にCa合金化が有望）を条件として機会を提供しており、FAA基準を満たす改善された難燃性を持つ合金（例：WE43、Ca含有合金）が開発されています。優れた機械的性能と、高い熱伝導率や難燃性などの応用特有のニーズに合わせて調整された新しいマグネシウム合金の継続的な開発は、自動車および航空宇宙産業の両方においてHPDCマグネシウム合金の強力で明るい未来を示唆しています。

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9. 著作権:

• 本資料は、「Sophia Fan, Xu Wang, Gerry Gang Wang and Jonathan P. Weiler」による論文です。「Applications of High-Pressure Die-Casting (HPDC) Magnesium Alloys in Industry」に基づいています。
• 論文の出典: http://dx.doi.org/10.5772/intechopen.110494

本資料は上記の論文に基づいて要約されており、商業目的での無断使用は禁じられています。
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