Process optimization for high integrity magnesium automotive components

在过去的15年里，镁在汽车中的使用量以每年约15%的速度显著增长。2007年车型的平均镁含量约为6公斤，预计到2020年将增加到160公斤。目前，镁合金的汽车应用是通过传统的高压铸造(HPDC)工艺生产的，这导致材料的孔隙率高而强度低。最近的研究表明，挤压铸造工艺能够显着消除镁合金的气孔和其他铸造缺陷。然而，与传统的HPDC相比，挤压铸造的成本相对较高，因为工艺操作和工具成本较高。为了以具有竞争力的成本最大限度地提高镁合金挤压铸件的工程性能和质量，需要优化挤压铸造工艺。

Over the past 15 years, magnesium (Mg) usage in automobiles has significantly increased by about 15% annually. The average Mg content in the 2007 model cars was about 6 kg, and is expected to increase to 160 kg by 2020. Currently, Mg automotive applications are produced by conventional high pressure die casting (HPDC) processes, which result in materials with high porosity content and low strengths. Recent studies have demonstrated that the squeeze casting process is able to significantly eliminate porosity and other casting defects in magnesium alloys. However, squeeze casting is relatively costly compared with conventional HPDC due to higher process operation and tooling costs. To maximize the engineering performance and quality of Mg squeeze castings at a competitive cost, the squeeze casting process needs to be optimized.