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A High Integrity Magnesium Automotive Castings (HI-MAC) project is the most recent magnesium project to receive approval and funding under the United States Department of Energy’s (DOE) cooperative agreement with the U.S. Automotive Materials Partnership (USAMP) of–the United States Council for Automotive Research (USCAR). The estimated four-year, $6 million project will help develop metalcasting process techniques and tools required to manufacture higher integrity cast magnesium components for the automotive industry. The U.S. Energy Department will provide $3 million in cash funding through its cooperative agreement with USAMP, while an additional $3 million will come through in-kind efforts of the project participants. The project proposal was developed largely through the efforts of an American Foundry Society team made up of Bruce Cox, DaimlerChrysler Corporation; Steve Robison, AFS Inc.; Don E. Penrod, Manufacturing Services & Development Inc.; and Dave Weiss, Eck Industries. The need for lightweight material in automotive production is primarily driven by the demand for better fuel efficiency and reduced exhaust emissions. Magnesium castings can contribute to improving a vehicle’s fuel efficiency by reducing the overall weight of vehicles. Additional potential benefits of lower weight include the reduction of exhaust emissions and better overall vehicle performance. The HI-MAC project will build upon the efforts and successes of the current USAMP Structural Cast Magnesium Development (SCMD) project. SCMD, which is scheduled to end this June, has demonstrated the effectiveness of magnesium castings when used in structural applications. HI-MAC will continue the research and development process of high integrity magnesium castings by addressing three key issues: development of casting tools, casting process development and infrastructure development. Since existing high pressure diecasting methods have limitations, HI-MAC will focus on developing processes for using magnesium in low pressure permanent mold and squeeze casting processes, which are commonly used in aluminum casting. The ultimate goal of the HI-MAC project is to develop cost-effective, high integrity cast magnesium automotive components. High integrity castings are defined by the project team as sound castings with low porosity; a lack of objectionable oxides and inclusions; and having consistently high ductility and strength. Previous efforts to develop the use of magnesium castings in automotive applications resulted in the SCMD project’s successful redesign of the front cradle for the 2006 Chevrolet Corvette Z06 from cast aluminum to a cast magnesium design, resulting in a 35 percent weight reduction. The HI-MAC team believes that similar reductions can be achieved in other suspension and chassis components with the use of magnesium castings. About USCAR Founded in 1992, The United States Council for Automotive Research facilitates cooperative research among DaimlerChrysler Corporation, Ford Motor Company and General Motors Corporation, which share the common goal of strengthening the technology base of the U.S. automotive industry. For more information, visit its Web site at www.uscar.org.
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