산업 분야에서의 고압 다이캐스팅(HPDC) 마그네슘 합금 응용

본 소개 자료는 "[IntechOpen]"에서 출판한 논문 "[Applications of High-Pressure Die-Casting (HPDC) Magnesium Alloys in Industry]"를 기반으로 작성되었습니다.

1. 개요:

• 제목: Applications of High-Pressure Die-Casting (HPDC) Magnesium Alloys in Industry (산업 분야에서의 고압 다이캐스팅(HPDC) 마그네슘 합금 응용)
• 저자: Sophia Fan, Xu Wang, Gerry Gang Wang and Jonathan P. Weiler
• 발행 연도: 2023 (논문 내 저작권 표기 기준)
• 발행 학술지/학회: IntechOpen (서적 "Magnesium Alloys – Processing, Potential and Applications" 내 챕터)
• 키워드: 고압 다이캐스팅(HPDC), 마그네슘 합금, 주조성, 자동차, 항공우주, 경량화 (high pressure die cast (HPDC), magnesium alloy, castability, automotive, aerospace, lightweighting)

2. 초록:

고압 다이캐스팅(HPDC) 마그네슘 합금은 주로 내연기관(ICE) 차량의 요구사항에 따라 자동차 산업에서 다양한 응용 분야를 보여왔습니다. 자동차 산업이 전기차(EV) 아키텍처로 전환됨에 따라, 주행 거리 효율성을 개선하기 위한 새로운 응용 가능성이 매우 큽니다. 또한, 더 큰 크기의 자동차 다이캐스팅 부품에 대한 추세와 무게 감소로 인한 항공우주 응용 분야에 대한 관심이 증가하고 있습니다. 본 챕터에서는 ICE 차량에서의 전통적인 자동차 구조 응용뿐만 아니라, HPDC 마그네슘 합금의 현재 및 잠재적인 미래 EV 및 항공우주 응용 분야를 검토했습니다. 기존 차량에서 AM50, AM60, AZ91 및 AE44 마그네슘 합금을 사용한 구조 응용은 현대 EV에도 적용될 수 있습니다. 추가적으로, 더 높은 열전도율, 개선된 주조성, 우수한 고온 특성 및 난연성을 다양한 수준으로 갖춘 마그네슘 합금이 개발되어야 하며, 이는 배터리 및 항공우주 객실 관련 구조 재료를 대체하여 모든 안전 요구사항을 충족시키기 위함입니다. 우수한 주조성을 가진 몇 가지 새로 개발된 마그네슘 합금 또한 잠재적인 자동차 및 항공우주 응용을 위해 검토되었습니다.

3. 서론:

배출가스 및 연비 규제로 인해 차량 무게를 줄여야 할 필요성이 증가하고 있습니다. 따라서 경량화는 안전과 성능을 유지하면서 동력 효율성을 개선하기 위한 매우 중요한 주제가 되었습니다. 제품 최적화, 재료 대체 및 부품 통합과 같은 여러 경량화 전략은 밀도가 높은 구조 재료를 밀도가 낮은 재료로 대체함으로써 추진됩니다.
마그네슘 및 그 합금은 다른 자동차 금속에 비해 여러 장점을 가집니다. 마그네슘의 밀도는 1.74 g/cm³로, 알루미늄과 강철보다 현저히 낮습니다 [1]. 마그네슘 합금은 우수한 비강도, 뛰어난 자동화 가능성 및 주조성 특성을 가지며 셀프 스레딩 패스너 사용에 적합한 것으로 잘 알려져 있습니다 [2]. 일반적으로 사용되는 마그네슘 합금은 150°C 이상의 사용 환경에는 부적합할 수 있지만 [3, 4], 적절한 합금 원소를 추가하여 내열성 [5–7] 및 내식성 [8, 9] 마그네슘 합금이 개발되었습니다. 자동차 산업은 내연기관(ICE)에서 전기차(EV)로 파워트레인 아키텍처가 전환되는 과정을 겪고 있습니다. 마그네슘 합금의 열전도율 증가 개발은 배터리 관련 응용을 지원했습니다 [7]. 한편, 난연성은 마그네슘 합금의 뜨거운 주제였으며, 관련 연구는 상당한 진전을 이루어 항공우주 응용에 매우 가치가 있습니다 [10–19]. 이러한 장점 덕분에 마그네슘 합금은 자동차 산업에서 광범위하게 활용되는 가장 가볍고 인기 있는 구조용 금속 중 하나가 되었습니다.
산업계의 대부분 마그네슘 합금 부품은 Figure 1에 설명된 고압 다이캐스팅(HPDC) 공정 [20–21]을 통해 제조됩니다. HPDC 공정은 설계 및 제조에서의 매력적인 유연성, 우수한 다이 충전 특성 및 강철 구조물에 필요한 2차 공정 감소의 높은 효율성을 제공합니다. Figure 2는 여러 다른 공정으로 제조된 AZ91의 항복 강도를 비교합니다 [22–25]. HPDC 공정으로 생산된 제품의 높은 강도는 빠른 냉각 속도로 인한 매우 미세한 미세구조의 결과입니다. 현대 HPDC 기술을 사용하면 마그네슘 합금은 크고 얇은 벽과 복잡한 형상을 가진 거의 최종 형상(near-net shape) 제품으로 생산될 수 있으며, 뛰어난 구조적 및 기능적 성능을 보여주므로 특히 대량 생산을 위한 효율적이고 비용 절감적인 방법으로 널리 적용되었습니다.
본 챕터에서는 역사적 및 잠재적 자동차 및 항공우주 산업에서의 HPDC 마그네슘 합금 응용을 검토하여 성공적인 사례와 진행 중인 개발 현황에 대한 전반적인 이해를 제공할 것입니다.

4. 연구 요약:

연구 주제 배경:

자동차 및 항공우주 산업은 연비/에너지 효율 및 성능 향상을 위해 차량 경량화에 대한 압박이 증가하고 있습니다(경량화). 마그네슘 합금은 낮은 밀도로 인해 매력적인 후보 재료입니다. 내연기관(ICE) 차량에서 전기차(EV)로의 전환은 경량 재료, 특히 특정 열 특성을 가진 재료에 대한 새로운 요구와 기회를 창출합니다. 항공우주 응용 분야 역시 경량화를 요구하지만 엄격한 난연성 요구사항이 있습니다.

이전 연구 현황:

HPDC 마그네슘 합금(예: AM50, AM60, AZ91, AE44)은 ICE 차량의 다양한 자동차 응용 분야에서 수십 년 동안 성공적으로 사용되어 왔습니다. 여기에는 내부 부품(계기판, 시트 프레임, 스티어링 휠), 차체 구조(라디에이터 서포트, 리프트게이트 이너, 도어 이너), 파워트레인 부품(오일 컨duit 모듈, 기어박스 하우징, 트랜스퍼 케이스), 섀시 부품(엔진 크래들, 서브프레임) 등이 포함됩니다. 연구는 합금화(예: RE 원소, Ca)를 통해 내식성, 내크리프성, 열전도율, 난연성과 같은 특성을 개선하는 데 중점을 두었습니다.

연구 목적:

본 챕터는 역사적 및 잠재적 자동차(ICE 및 EV) 및 항공우주 산업에서의 HPDC 마그네슘 합금 응용을 검토하는 것을 목표로 합니다. 성공적인 사례와 진행 중인 개발 현황에 대한 전반적인 이해를 제공하고, 이들 분야에서의 미래 성장 가능성을 강조하고자 합니다.

핵심 연구:

본 연구는 다양한 차량 시스템에 걸친 HPDC 마그네슘 합금의 특정 응용을 검토합니다:

• 내장: 계기판(IP)/크로스카빔(CCB), 시트 프레임, 스티어링 휠, 디스플레이 브래킷, 센터 콘솔, 리어 서포트 브래킷(RSB). 예시로는 JLR CCB의 진화(Figure 4), 다양한 시트백(Figure 5), 기타 내장 부품(Figure 6, Figure 7)이 포함됩니다.
• 차체: 루프 프레임, 마그네슘 라디에이터 서포트(MRS)(Figure 8), 프론트 오브 대시(FOD), 스페어 타이어 캐리어(STC)(Figure 9), 리프트게이트/해치백 이너, 사이드 도어 이너.
• 파워트레인: 엔진 프론트 커버, 오일 컨duit 모듈, 기어박스 하우징, 트랜스퍼/트랜스미션 케이스(Figure 10). AE44 및 AZ91D 사용이 언급됩니다.
• 섀시: 엔진 크래들, 서브프레임, 휠(주로 단조). 부식 및 기공이 주요 관심사입니다.
• 기타 자동차: 스트럿 타워 브레이스(Figure 11).
• 현재 EV 응용: ICE 응용의 이전 가능성(예: CCB, 프론트 엔드 캐리어, 도어 프레임). EV 특정 응용으로는 온보드 차저 하우징(Figure 12a) 및 잠재적 배터리 트레이(Figure 12b). 열전도율(Figure 13) 및 개선된 열 특성과 주조성을 가진 합금 개발(예: DSM-1, Mg-Al-Zn-RE-Ca, Mg-RE-Zn, Mg-La-Al-Mn)에 중점을 두며, RE 용해도(Figure 14)를 고려합니다.
• 항공우주 응용: 역사적 사용(예: F-80C, B-36, TU-95MS) 및 경량화 요구와 개선된 난연성으로 인한 최근 재도입 노력. 난연성 표준(FAA Chapter 25) 및 합금 원소(Ca, RE)의 저항성 개선 역할(Figure 15) 논의. 난연성, 주조성, 비용의 균형을 맞춘 합금(예: WE43 및 Ca 함유 합금 - ZACE05613, AMXS6020) 개발.

5. 연구 방법론

연구 설계:

본 연구는 포괄적인 문헌 검토 논문입니다. 출판된 문헌, 학회 발표 자료, 특허 및 산업 사례 연구 정보를 종합합니다.

데이터 수집 및 분석 방법:

데이터는 인용된 참고문헌 [1-152]에서 수집되었으며, 여기에는 학술 논문, 기술 보고서, 산업 간행물 및 특허가 포함됩니다. 분석은 역사적 및 현재 응용 요약, 다양한 마그네슘 합금의 특성 및 성능 비교(예: 기계적 특성, 부식, 열전도율, 난연성), 합금 개발 및 응용 요구사항(특히 EV 및 항공우주용)의 동향 파악, HPDC 마그네슘 합금 사용의 장점 및 과제 논의를 포함합니다.

연구 주제 및 범위:

본 연구는 고압 다이캐스팅(HPDC) 마그네슘 합금의 응용에 중점을 둡니다. 범위는 다음과 같습니다:

• 내연기관(ICE) 차량에서의 전통적인 응용 (내장, 차체, 파워트레인, 섀시).
• 배터리 관련 부품을 포함한 전기차(EV)에서의 현재 및 잠재적 응용.
• 항공우주 산업에서의 역사적 및 잠재적 응용.
• 사용된 주요 마그네슘 합금 (AM50, AM60, AZ91, AE44, WE43 및 최신 개발 합금).
• 관련 재료 특성: 기계적 강도, 연성, 주조성, 내식성, 열전도율, 난연성.
• HPDC 공정의 역할.

6. 주요 결과:

주요 결과:

• HPDC 마그네슘 합금(AM50, AM60, AZ91, AE44)은 경량화 잠재력, 우수한 비강도, HPDC를 통한 뛰어난 주조성 덕분에 복잡한 부품 통합을 가능하게 하여 수십 년 동안 자동차 산업에서 널리 채택되었습니다.
• 주요 전통적 응용 분야에는 계기판, 크로스카빔, 시트 프레임, 스티어링 휠, 라디에이터 서포트, 스페어 타이어 캐리어, 리프트게이트 이너, 도어 이너, 파워트레인 케이싱 및 엔진 크래들과 같은 섀시 부품이 포함됩니다.
• ICE 차량용으로 개발된 많은 구조 응용은 EV 아키텍처로 직접 이전 가능합니다.
• EV는 특히 배터리 관리 시스템을 위한 높은 열전도율과 같은 새로운 요구사항을 도입합니다. 우수한 주조성과 기계적 특성을 유지하면서 개선된 열전도율을 가진 HPDC 합금(예: 낮은 용해도를 가진 RE 원소 La, Ce 함유) 개발 연구가 진행 중입니다.
• 역사적으로 부식 및 난연성 문제로 제한되었던 항공우주 응용은 FAA 표준을 충족하는 개선된 난연성을 가진 합금(예: WE43, Ca 함유 합금)의 발전으로 인해 새로운 잠재력을 보여줍니다. 비용 효율적이고 주조 가능한 솔루션(특히 Ca 합금화)이 주요 초점입니다.
• HPDC 공정은 복잡하고 얇은 벽의 마그네슘 부품을 대량 생산에 효율적으로 제조하는 데 중요합니다.
• 부식 관리(특히 갈바닉 부식), 일부 신규 합금의 주조성 개선, 중요 응용 분야에서의 기공 제어, 비용 경쟁력 등의 과제가 남아 있습니다.
• 우수한 기계적 특성과 높은 열전도율 또는 난연성과 같은 응용 특정 요구를 결합한 새로운 합금 시스템이 개발되고 있습니다.

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.

그림 이름 목록:

• 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. 결론:

본 검토는 경량화 요구와 HPDC 공정의 장점에 힘입어 자동차 산업에서 내장, 차체, 파워트레인 응용 분야에 HPDC 마그네슘 합금(연성용 AM50/AM60, 강도/내식성용 AZ91D, 고온용 AE44 등)이 광범위하고 성공적으로 사용되었음을 강조합니다. 이러한 구조 응용 중 다수는 EV 아키텍처로 이전 가능합니다. 또한, HPDC 마그네슘 합금은 온보드 차저 하우징 및 배터리 트레이와 같은 EV 특정 부품에 상당한 잠재력을 보여주지만, 주조성과 열전도율을 최적화하기 위한 개발이 진행 중입니다. 항공우주 산업 역시 FAA 표준을 충족하는 개선된 난연성을 가진 합금(예: WE43, Ca 함유 합금) 덕분에 기회를 제공하며, 비용 효율적인 난연성 개선(특히 Ca 합금화)이 주요 초점입니다. 우수한 기계적 성능과 함께 맞춤형 특성(예: 우수한 열전도율, 난연성)을 결합한 새로운 마그네슘 합금의 지속적인 개발은 자동차 및 항공우주 산업 모두에서 HPDC 마그네슘 합금의 강력하고 밝은 미래를 시사합니다.

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9. 저작권:

• 본 자료는 "Sophia Fan, Xu Wang, Gerry Gang Wang and Jonathan P. Weiler"의 논문입니다. "[Applications of High-Pressure Die-Casting (HPDC) Magnesium Alloys in Industry]"를 기반으로 합니다.
• 논문 출처: http://dx.doi.org/10.5772/intechopen.110494

본 자료는 상기 논문을 바탕으로 요약되었으며, 상업적 목적의 무단 사용을 금지합니다.
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