S. Schumann

The Paths and Strategies for Increased Magnesium Applications in Vehicles

The use of magnesium in motor vehicles today and in future depends on numerous technical and economical factors, though the cost factor is essential. How might use of magnesium in vehicles develop, what prerequisites are necessary, what R&D efforts are required These questions will be addressed as follows based on component and project examples. The main focus of the current magnesium applications can be seen in the drive train and in the interior. In the short term, these applications will be further expanded: doubling the amount is feasible. This will be supported by the currently developed Mg alloys with extended application potential (creep resistance). Mg components in the body, Mg-sheets and Mg-extrusions applications will appear initially in niche-market and premium vehicles. This can prepare the way for and eventually lead to greater use of Mg in volume-production models as part of a multi-material design concept. The essential prerequisites for such increased use of magnesium will be discussed.

Properties and Processing of Magnesium Wrought Products for Automotive Applications

The application of magnesium as construction material is a substantial constituent for the implementation of lightweight construction concepts in the automotive manufacture. The magnesium wrought alloys open a broad application scope by their improved characteristic profile compared with magnesium cast alloys. Magnesium profile structures are particularly interesting due to their combination of high strength and ductility for automobile applications. Dependent on the individual component requirements different areas of application, e.g., window frameworks, seat and carrier structures, are conceivable. Under the aspects of lightweight construction magnesium sheet metals are particularly suitable for the application in the external vehicle structure. Particularly high demands are made of the sheet metals concerning surface quality and corrosion.

Effect of HPDC Parameters on the Performance of Creep Resistant Alloys MRI153M and MRI230D

The growing demand for the use of magnesium alloys in the production of automotive powertrain components led to the development of creep resistant diecasting alloys MRI153M and MRI230D. The present paper addresses the main high-pressure die casting parameters, which significantly affect the performance of components, produced of these new alloys. A systematic study was carried out in order to correlate die-casting parameters to the performance of new alloys. The results obtained clearly indicated that optimization of molten metal and die temperatures, injection profile parameters and lubrication mixtures allowed to improve the die castability and service properties of the new alloys and produce high performance components with intricate geometry. This was manifested by production of several practical demonstrators such as gearboxes, oil pans, oil pumps and crankcases.

High Temperature Mg Alloys for Sand and Permanent Mold Casting Applications

The need to reduce weight of large and heavy components used by the automotive and aerospace industries such as engine block, cylinder head cover and helicopter gearbox housing has led to the development of new Mg gravity casting alloys hat provide adequate properties and cost effective solution. The new Mg gravity casting alloys are designed for high stressed components that operate at a temperature up to 300°C. These new alloys exhibit excellent mechanical properties and creep resistance in T-6 conditions. The present paper aims at introducing three new Mg gravity casting alloys designated MRI 201S, MRI 202S and MRI 203S, which were recently developed by the Magnesium Research Institute of DSM and VW. Apart from the excellent high temperature performance of these alloys, they provide adequate castability and dimension stability along with good weldability and corrosion resistance. In addition, the paper will also introduce practical applications that demonstrate the capabilities of the newly developed alloys.

Material-Specific Joining Techniques for Magnesium Body Structures

In order to achieve further reductions in the weight of the body-in-white, efforts are being made in the field of car design to replace structural elements by magnesium components. In addition to the use of extrusion and sheet metal processes, die casting in particular is an especially important method of producing thin-walled, highly integrative components, because of the very good casting properties of magnesium. Integrating of die casted components into a vehicle structure calls for joining techniques which offer the maximum utilization of the materials of the joined parts under operating loads. This article discusses the necessity for material-specific joining techniques for future magnesium body structures. Using the example of aluminium/magnesium joints, the article describes the benefits of different joining techniques with regard to their efficient use of material in the case of both quasi-static and dynamic loads.

Neue Magnesium- Blechprodukte für den Automobilbau

Intensive Leichtbaubestrebungen fuhren zu einem wachsenden Interesse der Automobilindustrie an neuen, leistungsfahigen und umweltvertraglichen Werkstoffalternativen. Hierzu zahlt auch Magnesium. Im Gegensatz zu bereits etablierten druckgegossenen Bauteilen sind hoherduktile Magnesium-Blechprodukte bisher nicht im Einsatz. Gemeinsame Entwicklungsaktivitaten der Salzgitter AG und der Volkswagen AG zielen deshalb auf neue Einsatzmoglichkeiten von Magnesium-Blechen in der Fahrzeugkarosserie. Grundlagenuntersuchungen und die erfolgreiche Mg-Blechherstellung im Pilotmaβstab sowie die Fertigung erster Pressteile unterstreichen das Leichtbaupotenzial des Magnesiumblechs fur groβflachig dunnwandige Fahrzeugkomponenten.