Magnesium Alloys and Applications in Automotive Industry

1. Overview:

  • Title: Magnesium alloys and applications in automotive industry
  • Author: Nima Khademian, Yaser Peimaei
  • Publication Year: August 2021
  • Publishing Journal/Academic Society: Fourth International Conference on Interdisciplinary Studies in Nanotechnology (Conference Paper)
  • Keywords: Magnesium alloys, Manufacturing methods, Automobile, Micro/nanostructures
Fig. 2. Improved part design
Fig. 2. Improved part design

2. Research Background:

  • Social/Academic Context of the Research Topic:
    • The automotive industry is increasingly focused on improving fuel economy and reducing emissions.
    • Light weighting of vehicles is a key strategy to achieve these goals.
    • Substituting conventional heavier materials like steel and cast irons with lighter alternatives such as aluminum and magnesium is a growing trend.
    • Magnesium, being the lightest structural metal, is considered a promising material for automotive applications.
  • Limitations of Existing Research:
    • While the paper doesn't explicitly detail limitations of prior research, it implies a continuous need for advancements in magnesium alloy technology and its application in vehicles.
    • The ongoing desire to identify challenges, solutions, and opportunities related to magnesium use suggests that existing research is still evolving and requires further exploration.
  • Necessity of the Research:
    • Weight loss in vehicles is crucial for both combustion and electric vehicles to meet stringent fuel economy and emission standards.
    • Reducing vehicle mass improves performance attributes such as acceleration, braking, and handling.
    • Magnesium offers superior heat dissipation and heat transfer due to high thermal conductivity.
    • Magnesium alloys exhibit excellent ability in shielding electromagnetic interruption.
    • Magnesium alloys can reduce noise and vibrations compared to typical metals and increase stiffness.
    • Weight reduction in dynamic structures is significantly more impactful than in static structures, making magnesium particularly beneficial for automotive components.

3. Research Purpose and Research Questions:

  • Research Purpose:
    • To investigate the challenges, solutions, and opportunities associated with utilizing magnesium in automotive applications.
    • To provide an overview of the historical, current, and potential future structural applications of magnesium within the automotive industry.
  • Key Research Questions:
    • What are the advantages of employing magnesium alloys in automotive design and manufacturing?
    • What are the primary challenges and limitations associated with the increased use of magnesium alloys in vehicles?
    • What are the current applications of magnesium alloys in the automotive sector, and what are the potential areas for future expansion?
    • How can manufacturing methods be optimized to facilitate greater adoption of magnesium alloys in vehicle production?
  • Research Hypotheses:
    • The paper does not explicitly state research hypotheses. The research is primarily exploratory and descriptive, aiming to synthesize existing knowledge and identify trends and future directions.

4. Research Methodology

  • Research Design:
    • The research employs a literature review approach, synthesizing information from existing studies, industry reports, and historical data related to magnesium alloys in the automotive industry.
  • Data Collection Method:
    • The study relies on secondary data gathered from published research papers, conference proceedings, and industry-related publications.
    • Historical examples of magnesium applications in vehicles are also considered.
  • Analysis Method:
    • The analysis is primarily qualitative, focusing on summarizing and interpreting the existing body of knowledge on magnesium alloys in automotive applications.
    • The paper identifies key trends, benefits, challenges, and future directions based on the reviewed literature.
  • Research Subjects and Scope:
    • The research focuses on magnesium alloys as a material and their specific applications within the automotive industry.
    • The scope encompasses various aspects, including material properties, manufacturing methods (especially die casting), automotive component design, and the historical evolution of magnesium use in vehicles.

5. Main Research Results:

  • Key Research Results:
    • Light weighting is a major focus for fuel economy in the automotive industry, with 39% of companies prioritizing it in 2017.
    • Magnesium alloys offer substantial weight savings compared to steel and aluminum, with potential weight reductions of up to 60%.
    • Current average magnesium usage in vehicles ranges from 4-30 kg, with an industry target of exceeding 80 kg per vehicle by 2030.
    • Magnesium alloys are utilized in diverse automotive components, including chassis, interior parts (seat bases, instrument panels), exterior panels (roofs, frames), and powertrain components.
    • Pressure die casting is the predominant manufacturing method for producing magnesium automotive parts due to its excellent casting properties and ability to create complex shapes with thin walls.
    • Magnesium die castings made of high-ductility alloys like AM50 and AM20 offer a combination of high strength, extreme rigidity, low weight, and cost-effectiveness.
  • Statistical/Qualitative Analysis Results:
    • Fuel Economy Focus (2017 Data): 39% light weighting, 29% engine efficiency, 26% vehicle electrification, 6% downsizing.
    • Weight Saving Potential: Aluminum (2.7 g/cm3) can save 50% weight, Magnesium (1.8 g/cm3) can save 60% weight, glass fiber composite (~1.1-2.5 g/cm3) can save 30% weight, and carbon fiber composite (~1.8 g/cm3) can save 60% weight.
    • Vehicle Weight Breakdown: 35% body, 34% chassis and suspension, 27% powertrain, and 4% other.
    • Mass Reduction Example (Cadillac ATS): Efficient material utilization (lightening holes & scalloped flanges) eliminated 2.8 kg.
    • Mass Reduction Example (USCAR Sigma project): Part consolidation in sun visor attachment design.
    • Magnesium front end structure: 45% weight reduction compared to steel, 56% reduction in part count (USCAR/USAMP project).
  • Data Interpretation:
    • The data underscores the significant potential of magnesium alloys in achieving automotive weight reduction targets.
    • The statistical breakdown of vehicle weight and fuel economy strategies highlights the importance of light weighting as a primary approach.
    • Examples of mass reduction through efficient material utilization and part consolidation demonstrate practical engineering strategies for implementing magnesium in vehicle design.
    • The success of magnesium die castings, particularly with alloys like AM50 and AM20, indicates their suitability for demanding automotive applications.
  • Figure Name List:
    • Fig. 1. Fuel consumption
    • Fig. 2. Improved part design
    • Fig. 3. Application of magnesium in automobiles
    • Fig. 4. Application of magnesium in automobiles
    • Fig. 5. Application of magnesium in automobiles
Fig. 1. Fuel consumption
Fig. 1. Fuel consumption
Fig. 4. Application of magnesium in automobiles
Fig. 4. Application of magnesium in automobiles
Fig. 5. Application of magnesium in automobiles
Fig. 5. Application of magnesium in automobiles

6. Conclusion and Discussion:

  • Summary of Main Results:
    • Magnesium alloys present a compelling solution for reducing vehicle weight, contributing to improved fuel efficiency and enhanced vehicle performance.
    • Die casting stands out as the most effective and widely used manufacturing process for magnesium automotive components.
    • Despite the advantages, challenges persist in areas such as alloy development, optimizing manufacturing processes, and enhancing corrosion resistance to broaden magnesium's application scope.
  • Academic Significance of the Research:
    • This paper provides a valuable overview of the current state of magnesium alloy applications in the automotive industry.
    • It synthesizes information from diverse sources to highlight the material's potential and the ongoing research and development efforts in this field.
    • The review contributes to the academic understanding of lightweighting strategies and material selection in automotive engineering.
  • Practical Implications:
    • The findings encourage increased adoption of magnesium alloys in vehicle design and manufacturing to meet fuel economy and performance demands.
    • The paper emphasizes the need for continued innovation in magnesium alloy technology, particularly in addressing challenges related to corrosion and mechanical properties.
    • The discussion on manufacturing processes, especially die casting, provides practical insights for engineers and manufacturers working with magnesium alloys.
  • Limitations of the Research:
    • As a conference paper, the research is primarily a review and overview, lacking original experimental data or in-depth quantitative analysis.
    • The scope is broad, covering various aspects of magnesium in automotive applications, which may limit the depth of analysis in specific areas.

7. Future Follow-up Research:

  • Directions for Follow-up Research:
    • Developing novel magnesium alloys with enhanced properties, including improved ductility, fatigue strength, creep resistance, and corrosion resistance, is crucial for expanding applications.
    • Exploring and optimizing advanced manufacturing processes for magnesium components, such as hollow casting techniques and metal matrix composites, to further enhance performance and reduce costs.
    • Further research is needed to develop accurate material models for magnesium fracture behavior under crash loading conditions to facilitate safer and more efficient component design.
  • Areas Requiring Further Exploration:
    • Surface finishing and corrosion protection technologies for magnesium alloys require continuous improvement to ensure long-term durability in automotive environments.
    • Optimizing casting parameters, particularly for die casting processes, to minimize porosity and enhance the mechanical properties of magnesium components is essential for wider adoption.
    • Investigating the long-term performance and durability of magnesium components in real-world automotive applications is necessary to validate their reliability and identify potential areas for improvement.

8. References:

  • [1] Luo, A.A. (2013), Magnesium casting technology for structural applications, journal of magnesium and alloys 1.
  • [2] Abbott, T.B. et al., Designing with Magnesium: Alloys, Properties, and casting process.
  • [3] Dziubinska, A. (2016), The forming of magnesium alloy forgings for aircraft and automotive applications, Advances in Science and Technology Research Journal.
  • [4] Musfirah, A.H. et al. (2012), Manesium and aluminium alloys in automotive industry, Journal of Applied Sciences Research, 8 (9), 4865-4875.
  • [5] William J. (2016), Towards magnesium alloys for high-volume automotive applications, Scripta Materialia.
  • [6] Wu R., et al. (2015), Recent progress in magnesium -lithium alloys, International Materials Reviews, Vol 60, No2.
  • [7] Vorozhtsov, S., et al. (2016), Structure and Deformation Characteristics in Magnesium Alloy ZK51A Reinforced with AlN Nanoparticles, Prospects of Fundamental Sciences Development (PFSD), doi: 10.1063/1.4964542.
  • [8] X.H., et al. (2012), Si3N4 Nanoparticle Addition to ConcentratedMagnesium Alloy AZ81: Enhanced Tensile Ductility and Compressive Strength Muralidharan Paramsothy,, Jimmy Chan, Richard Kwok, Manoj Gupta, International Scholarly Research Network ISRN Nanomaterials.
  • [9] Bakhsheshi-Rad, H.R., et al. (2020), Carbon Nanotubes (CNTs)-Reinforced Magnesium-Based Matrix Composites: A Comprehensive Review, Somayeh Abazari,, Materials (MDPI).
  • [10] Haghshenas, M. (2020), Magnesium nanocomposites reinforced with rare earth element nanoparticles: nanoindentation driven response, NANOCOMPOSITES Vol. 6, No. 1, 22–30.
  • [11] Song, J., et al. (2020), Latest research advances on magnesium and magnesium alloys world wide, Jounal of Magnesium and Alloys, Vol 8.

9. Copyright:

This material was summarized based on the above paper, and unauthorized use for commercial purposes is prohibited.
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Tags: Applications; ,AUTOMOTIVE Parts; ,CAD; ,Casting Technique; ,Die casting; ,Efficiency; ,Electric vehicles; ,Magnesium alloys; ,Review