Magnesium and its alloys applications in automotive industry

This article introduces the paper ['Magnesium and its alloys applications in automotive industry'] published by ['Springer-Verlag London Limited'].

1. Overview:

• Title: Magnesium and its alloys applications in automotive industry
• Author: Mustafa Kemal Kulekci
• Publication Year: 2008
• Publishing Journal/Academic Society: International Journal of Advanced Manufacturing Technology
• Keywords: Magnesium, Mg components, Mg applications, Automotive industry, Transportation, Fuel economy

2. Abstracts or Introduction

The objective of this study is to review and evaluate the applications of magnesium in the automotive industry, highlighting its potential to significantly contribute to enhanced fuel economy and environmental conservation. The paper addresses current advantages, limitations, technological barriers, and future prospects of Magnesium (Mg) alloys within the automotive sector. It assesses the impact of magnesium usage in automotive applications on environmental conservation. Recent advancements in coating and alloying of Mg are discussed, focusing on improvements in creep and corrosion resistance properties of magnesium alloys for high-temperature and corrosive environments. The study concludes that reasonable pricing and enhanced properties of Mg and its alloys will drive substantial magnesium adoption. Compared to alternative materials, Mg alloys offer a weight reduction ranging from 22% to 70%. The increasing utilization of magnesium in automotive components is attributed to the growing understanding of Mg alloy forming processes.

3. Research Background:

Background of the Research Topic:

The automotive industry is driven by global trends towards manufacturing lighter, more environmentally friendly, safer, and cheaper vehicles [4]. Automakers are focused on reducing vehicle weight and limiting exhaust emissions due to legislative and consumer demands for safer, cleaner vehicles [7]. Carbon dioxide (CO2) emission is directly proportional to fuel consumption, making vehicle weight a critical design efficiency parameter [11]. Weight reduction is crucial not only for energy saving but also for reducing greenhouse gas emissions.

Status of Existing Research:

Auto manufacturing companies have invested significantly in research and development concerning Mg and its alloys. Volkswagen was the pioneer in applying magnesium in the automotive industry with its Beetle model [7]. Porsche's early work with magnesium engines dates back to 1928 [8]. Past material choices for certain auto parts included aluminium and some plastics. However, recent years have witnessed an increase in magnesium applications within the automotive sector [9]. Current research and development efforts are directed towards weight reduction, energy conservation, and minimizing environmental impact [10].

Necessity of the Research:

Environmental conservation is a primary driver for the focus on Mg and its alloys. The transportation industry's contribution to CO2 emissions necessitates weight reduction as a cost-effective strategy for decreasing fuel consumption and emissions [9, 16]. European and North American car producers aim for substantial fuel consumption and CO2 emission reductions [9, 16, 17]. Despite the increasing consumption of magnesium in recent decades, a significant portion is still used for alloying aluminium, with only about 34% directly utilized for magnesium parts [4, 19]. High cost remains a major barrier to wider magnesium adoption in the automotive industry, requiring competitive pricing for finished products.

4. Research Purpose and Research Questions:

Research Purpose:

The research aims to review the science, technology, and applications of magnesium and its alloys in the automotive industry, emphasizing their contribution to fuel economy and environmental conservation in light of recent advancements. It also intends to examine the current advantages, limitations, technological barriers, and future projections for the utilization of Mg alloys in this sector.

Key Research:

The key research areas explored in this study include:

• Evaluation of magnesium applications in the automotive industry.
• Analysis of advantages, limitations, and technological barriers to magnesium use.
• Assessment of future prospects for magnesium alloys in automotive applications.
• Investigation of the impact of magnesium usage on environmental conservation.
• Review of recent developments in coating and alloying of magnesium to improve material properties.

Research Hypotheses:

The paper does not explicitly state research hypotheses. However, implicitly, the study operates under the premise that:

• Increased use of magnesium alloys in automotive components leads to significant weight reduction and improved fuel economy.
• Overcoming limitations related to cost and material properties will enable massive adoption of magnesium in the automotive industry.
• Advancements in magnesium alloy processing and coating technologies are crucial for expanding magnesium applications.

5. Research Methodology

Research Design:

This study employs a review-based research design. It synthesizes existing literature and research findings to provide a comprehensive overview of magnesium applications in the automotive industry.

Data Collection Method:

The data collection method is based on a literature review of published articles, reports, and industry data related to magnesium alloys and their applications in automotive engineering.

Analysis Method:

The analysis method is qualitative, involving a descriptive synthesis and evaluation of the collected literature. The paper analyzes trends, challenges, and opportunities related to magnesium use in vehicles based on the reviewed sources.

Research Subjects and Scope:

The research focuses on magnesium and its alloys within the context of the automotive industry. The scope encompasses:

• Material properties of magnesium alloys relevant to automotive applications.
• Processing technologies for magnesium components.
• Applications of magnesium in various automotive parts.
• Factors influencing the adoption of magnesium, such as cost, performance, and environmental considerations.

6. Main Research Results:

Key Research Results:

• Magnesium alloys offer a 22% to 70% weight reduction compared to alternative materials in automotive components.
• Specific strength of magnesium is considerably higher than aluminium and iron, while specific stiffness is comparable (Figure 4).
• Cost of magnesium alloys has decreased relative to aluminium since 2004 (Figure 3).
• New magnesium alloys like AE42 and Mg-Al-Sr systems exhibit improved creep resistance (Figure 5, Figure 6).
• Teflon resin coating, obtained with aluminium vapour deposition, provides a low-cost, chromium-free corrosion-resistant coating for magnesium alloys (Figure 7).
• Die-casting is a primary fabrication method for magnesium automotive components.
• Automotive components made of Mg alloy and obtained weight reduction are shown in Figure 8.
• Examples of automotive components made of Mg alloys are shown in Figure 9.
• VW strategy of magnesium technology development is illustrated in Figure 11.

Analysis of presented data:

• Figure 1: Illustrates basic requirements for vehicle components, including Function, Weight, Ergonomics, Cost efficiency, Manufacturability, Safety, Quality, and Environmental Safety [1].
• Figure 2: Shows the relationship between vehicle mass and fuel consumption, demonstrating that reduced vehicle weight leads to improved fuel economy [5].
• Figure 3: Depicts changes in the prices of magnesium and aluminium, indicating a decrease in magnesium price relative to aluminium since 2004 [20].
• Figure 4: Compares basic structural properties of magnesium, aluminium, and iron, highlighting magnesium's superior specific strength [1].
• Figure 5: Compares creep deformation of die-cast Mg-alloys, showing improved creep resistance in AE42 and Mg-Al-Sr alloys compared to AZ91D [31].
• Figure 6: Shows creep resistance of new alloys in comparison to AZ91 and AE42 alloy at 135°C under stress of 85 MPa [17].
• Figure 7: Presents a schematic view of the cross-section for Teflon resin coating [34].
• Figure 8: Illustrates some automotive components made of Mg alloy and the obtained weight reduction.
• Figure 9: Provides examples of automotive components made of Mg alloys.
• Figure 10: Shows North American automotive magnesium usage [15].
• Figure 11: Illustrates VW strategy of magnesium technology development [7].

Figure Name List:

• Fig. 1 Basic requirements for vehicle components [1]
• Fig. 2 The relation between vehicle mass and fuel consumption [5]
• Fig. 3 Changes in the prices of magnesium and aluminium [20]
• Fig. 4 Comparison of basic structural properties of magnesium with Al and iron
• Fig. 5 Comparison at creep deformation of die-cast Mg-alloys (35 MPa, 150°C, 200 h) [31]
• Fig. 6 Creep resistance of new alloys in comparison to AZ91 and AE42 alloy at 135°C under stress of 85 MPa: (1) AZ91; (2) AE42; (3) MRI 155; (4) MRI 153; (5) MRI 154; (6) MRI 151; (7) MRI 152 [17]
• Fig. 7 Schematic view of the cross-section for Teflon resin coating [34]
• Fig. 8 Some automotive components made of Mg alloy and obtained weight reduction
• Fig. 9 Examples of automotive components made of Mg alloys (a: Engine block, b: Steering column module, c: Door frame / Key lock housing, d: Oil pan, e: Steering wheel, f: Transfer case/Transmission housing, g: Seat frame, h: Wheel)
• Fig. 10 North American automotive magnesium usage [15]
• Fig. 11 VW strategy of magnesium technology development [7]

7. Conclusion:

Summary of Key Findings:

The study concludes that magnesium alloys offer significant potential for weight reduction in automotive applications, contributing to improved fuel economy and reduced CO2 emissions. Key findings include the superior specific strength of magnesium, decreasing cost trends, and advancements in alloy development and coating technologies that address limitations such as creep and corrosion resistance. Die-casting remains the dominant manufacturing process, but further research into forming processes is needed to expand magnesium usage. While magnesium faces challenges like reactivity and galvanic corrosion, these can be mitigated through design and protective measures.

Academic Significance of the Study:

This review paper provides a comprehensive overview of the state-of-the-art in magnesium alloy applications within the automotive industry. It consolidates findings from various studies, offering valuable insights into the material's potential, limitations, and future directions. The paper serves as a handbook-level resource for experts and researchers in materials science, automotive engineering, and manufacturing technology.

Practical Implications:

The practical implications of this study are significant for the automotive industry. The findings support the increased adoption of magnesium alloys to meet growing demands for fuel efficiency and environmental regulations. The paper highlights specific areas for technological development, such as cost-effective alloying, improved corrosion protection coatings (like Teflon resin coating), and advanced forming techniques, which can enable wider and more effective use of magnesium in vehicle manufacturing.

Limitations of the Study and Areas for Future Research:

This study is limited to a review of existing literature and does not include original experimental research. Areas for future research include:

• Further development of magnesium alloys with enhanced creep resistance, particularly for high-temperature powertrain applications.
• Optimization of magnesium alloy forming processes, especially for sheet and extrusion applications, to overcome limitations imposed by the hexagonal crystal structure.
• Research into cost-effective and environmentally friendly surface treatments and coatings to improve corrosion resistance and address galvanic corrosion concerns.
• Life cycle assessments to fully quantify the environmental benefits of magnesium alloy substitution in vehicles, considering production, usage, and recycling phases.

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9. Copyright:

• This material is Mustafa Kemal Kulekci's paper: Based on "Magnesium and its alloys applications in automotive industry".
• Paper Source: DOI 10.1007/s00170-007-1279-2

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