Magnesium: Where Have We Been, Where Are We Going?

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Robert E. “Bob” Brown receiving a lifetime achievement L I]Z egZhZci ]^\] Xdhi VcY adl VkVâVWâîn d[ award from the IMA at their 2007 annual meeting in Vancouver, B.C., bV\cZh^jb VcY îh Vaadnh VgZ ]VbeZg^c\ XdbbZgX^Va Canada.1 egd_ZXihVcYdeZc^c\Yddgh[dgXdbeZi^c\bViZg^Vah egdYjXZY^c'%%+#I]^h^hVgZXdgY[dgldgaYbV\cZh^jb LI]ZXdbeZiî^kZegZhhjgZ[gdbdi]ZgbZiVah!eaVhi^Xh!Unusual Year for WorldegdYjXi^dc#¹=^hhjbbVgnX]Vgid[ldgaYl^YZbV\cZh^jb Magnesium in 2007 XdbedhîZh!VcYZkZclddY]VhcZkZgWZZc\gZViZg egdYjXi^dc^c'%%,^hh]dlc^cIVWaZ>!l]ZgZî^hhZZc L 6h VgZ5HFRUG3URGXFWLRQ³3ULFHV6N\URFNHWLQJ di]Zgh! i]Z bV\cZh^jb ^cYjhign ^h [VX^c\ i]Vis-'d[i]ZldgaYbV\cZh^jblVhegdYjXZY^chdbZ X]VaaZc\ZhedhZYWn\adWValVgb^c\VcYZck^gdcbZciVa -%eaVcih^c8]^cV!VaaWni]ZgbVagZYjXi^dcd[YdadbîZ XdcXZgch By Robert E. Brown, Contributinglî][Zggdhâ^XdcE^Y\ZdcegdXZhh# Editor L Bdhi eg^bVgn bV\cZh^jb ^h egdYjXZY ^c 8]^cV jiâô^c\Vi]ZgbVaegdXZhhE^Y\Zdci]Vi^hcdl[VXZYIntroduction lî] Zb^hh^dc gZYjXi^dc gZfj^gZbZcih Wn i]Z 8]^cZhZ \dkZgcbZcin a review that was done for Light Metal Age in February L2007, BV\cZh^jb it was predicted lVh gZ_ZXiZY that “2007 Wn may i]Z bring AdcYdc even BZiVamore :mX]Vc\Z^c'%%,VhVigVYZYXdbbdYînbZiVaYjZidi]Zstartling news (for the magnesium industry).” That hbVaahôZd[i]Z^cYjhignVcYi]ZXdcigdad[egdYjXi^dcis exactly what happened. Magnesium has tended to IbeWn8]^cV a metal that is largely ignored by the general public andL >cVcZl:jgdeZVc8dbbjcînegd\gVb!bV\cZh^jbmedia except when a large fi re at a plant makes the nationallâa WZ XaVhh^ÃZY news. World Vh V interest ediZci^Vaan in magnesium ]VoVgYdjh has X]Zb^XVa! fl ared up,VcY however. bV\cZh^jb The ^bedgiZY recent rapid ^c i]Z increase Xdjcig^Zh in magnesium jcYZg i]Z prices_jg^hY^Xi^dcd[i]Zegd\gVblâa[VXZbdgZhXgji^cn has forced major users to pay attention. Although magnesiumL 8dbeVgZY production lî] XdbeZiî^kZ set new production bViZg^Vah! records, bV\cZh^jb the pricebVg`Zi^c\$hVaZh$Zc\^cZZg^c\^c[gVhigjXijgZVcYhjeedgi was still skyrocketing at the end of 2007. ^hPlatts aVX`^c\ Metals ^c i]Z Week LZhi sponsored VcY hdbZ an aluminum d[ i]Z di]Zg seminar aVg\Zhi at MarcoediZci^VagZ\^dcVabVg`Zih[dgbV\cZh^jb Island, Florida in January 2008.1 Susan Slade from USL @cdl"]dlVcYigV^c^c\d[Zc\^cZZghVcYiZX]cdad\^hih Magnesium LLC, the only remaining magnesium producer^cldg`^c\lî]bV\cZh^jbVcYîhVaadnhVeeZVghidWZ in North America, was invited to speak. Table I. MagnesiumWorldwide magnesium production forproduction 2007. for 2007 (e = estimated).2 AlthoughYZXa^c^c\^ci]ZLZhi!VegdXZhhbVYZldghZWnaVX`d[ the magnesium presentation was held on the lastVkVâVWâînd[i]ZbZiVa day, near the end of the session when many of the productionGZ\VgY^c\bV\cZh^jbXdchjbei^dc^c'%%,!7dW\VkZ which would be on-stream in 2010. “We expect attendeesLEZhh^b^hihndj`cdll]dndjVgZXVcVYYidi]Z are normally making their tee times, a large toVcZhi^bViZd[*.(!*%%bi!VcYWgd`Zdjii]ZbV_dgVcY be fully on-stream (with the 9,000 tpy expansion) by numbera^hi of the aluminum industry people stayed around thisb^cdgbVg`ZihZ\bZcih[dgi]ZeZg^dY'%%&"'%%,IVWaZ summer,” a company executive said. The additions to attend theBV\cZh^jbIdYVn'%%*¶'%%- session and to ask questions about the come>># =Z after cdiZY a 2007 i]Vi! that Vai]dj\] saw the lgdj\]i U.S. market bV\cZh^jb lose supply ]Vh future, especially with regard to supply and pricing. sourcesadc\ WZZc and V spot b^cdg prices XViZ\dgn soar to d[ record jhZ! cZllevels. YZkZadebZcih Anc]^h6egâ'%%-VccjVabV\cZh^jb of magnesium used in many aluminum alloys, $1.50=jciZgil^cgdaaXVhiZgidXdci^cjdjhanXVhibV\cZh^jb per pound during 2006 and almost all of 2005. especially^cYjhign gZk^Zl!can stock GdWZgi alloys, :# 3004 ¸7dW¹ and 7gdlc! 5182. McHale Xdcig^Wji^c\ used OneVaadnXdâh# producer reported at the end of 2007 that he had alloyZYîdg[dg 5182 AB6as an VcYejWa^h]Zgd[i]Zexample.2 At 4.5% magnesiumBV\cZh^jbBdci]an the alloy concludedI]Z 8VcVY^Vc spot business eZgheZXi^kZ at $3.05 dcper pound eg^bVgn and bV\cZh^jb suggested isGZk^Zl still ;^\jgZ&!hjbbVgôZYi]ZjcjhjVahiVijhd[i]Zprimarily P1020 aluminum but profi t margins can pricesegZhZciZY could Wn go ca^cZlî]]^h have more ^chigjXi^kZVWdjii]ZXVjhZhd[i]ZXjggZcihjeean$YZbVcYCanada: For the fi rst time since 1941, there was no thanZVga^ZgegZY^Xi^dc^c;ZWgjVgn'%%,i]Vi¸'%%,bVnWg^c\ doubled over the past 18 months. Prices now hover magnesiumhXZcVg^d!YZhXg^W^c\Ãghii]Z]^hidg^Xh]^[i^cbV\cZh^jb production in Canada. Becancour, the aroundZkZcbdgZhiVgia^c\cZlh[dgi]ZbV\cZh^jb^cYjhign!¹ $3 per pound for spot purchases after stalling at( egdYjXi^dch^cXZ&.&*VcYîh^cÄjZcXZdceg^X^c\!i]Zc large 45,000 mtpy electrolytic) production plant with $1.20'%%,ijgcZYdjiidWZjcjhjVa^cYZZY!lî]bV\cZh^jb per pound or less as recently as 2006. anVcVano^c\ additional i]Z igZcYmagnesium idYVn# recyclingEg^XZh gdhZ plant h^bjaiVcZdjhan owned and egdYjXi^dcMcHale said hZii^c\ that in cZl January egdYjXi^dc 2006 aluminum gZXdgYh l]âZwas $1.13 i]Z operated^c '%%, lî] by Norsk i]Z Xadh^c\ Hydro d[in Cdgh`Quebec, =nYgd»h was shut )*!%%% down bien and pereg^XZlVh^c]^hldgYh¸h`ngdX`Zi^c\#¹7dWed^ciZYdjii]Vi pound and magnesium just $1.22 per pound. At has7XVcXdjg been sold eaVci to the ^c partnership FjZWZX ;^\jgZh of EDS Decommissioning ' VcY (! aZVk^c\ theeg^XZh]VkZbdgZi]VcYdjWaZY^ci]Z&-bdci]hWZ[dgZ seminar, McHale used a price of $2.85 per pound Canada8VcVYVlî]cdeg^bVgnbV\cZh^jbegdYjXi^dc[dgi]Z Inc. and Industrial Asset Management LLC, for6egâ'%%-/¸Eg^XZhcdl]dkZgVgdjcY(eZgedjcY[dg magnesium for his calculations while aluminum USAÃghii^bZh^cXZ&.)&#Lî]eg^bVgnbV\cZh^jb^c'%%, of Princeton, New Jersey (Figure 1). The facility remainedhediejgX]VhZhV[iZghiVaa^c\Vi&#'%eZgedjcYdgaZhhVh at $1.13 per pound. The impact of the rise in willVi i]Z be XgdhhgdVYh dismantled! i]Z and \adWVa sold djiadd` for relocation ^c 8VcVYV by itemsWZ\h [dg of magnesiumgZXZcianVh'%%+#¹ price shaved seven cents per pound off the equipment.hiVWâînd[hjeean!lî]gZVXi^kVi^dcd[8VcVY^Vcegd_ZXih The technology is also for sale. The idled margin,6h [Vg or Vh “fabrication egdYjXi^dc ^hspread” XdcXZgcZY! as McHale 7dW gZk^ZlZYcalled it, i]Zfor 63,000]ZaYdjiVhVedhh^WaZWji]^\]g^h`[jijgZ]deZ# mtpy electrolytic plant, Magnola, that was built by alloyegZhZcildgaYl^YZhîjVi^dci]jh/¸>cheîZd[i]Z[VXii]Vi 5182. Noranda,6jidbdi^kZBV\cZh^jb9ZkZadebZcih^c8]^cV was put up for sale and has had no/ buyers.I]ZegZhZci Now i]ZgZ ^h cd adc\ZgMagnesium Vcn bV\cZh^jb Production WZ^c\ egdYjXZY ^c hiVijhd[bV\cZh^jb^ci]Z8]^cZhZVjidbdi^kZ^cYjhign owned by Xstrata, the plant is going to be dismantled.*!+ 8VcVYV!HZgW^V!dgi]ZJ`gV^cZ!idiValdgaYegdYjXi^dc lVhZmiZch^kZangZedgiZYWn9g#9V_jc8]ZcGossan Resources in Canada has announced# GZedgi^c\ that they d[In bV\cZh^jb spite of the fact ^h Zhi^bViZY that there idis no WZ longer ,*,!*%% any bi magnesium ^c '%%,! havedci]Z'%%,8]^cVBV\cZh^jb6jidbdi^kZ8dc[ZgZcXZ the rights for a new technology for the production beingVc^cXgZVhZd[Veegdm^bViZan&*[gdbi]Z,%,!*%%bi produced in Canada, Serbia, or the Ukraine, of]ZaY^c?jcZ^c8]dc\f^c\!8]^cV!9V_jcYZhXg^WZhi]Z magnesium from dolomite. It has been reported total world production of magnesium is estimated to be 2757,500 mt in 2007, an increase of approximately 15% from the 707,500 mt produced in 2006. This is a record for world magnesium production. China again produced about 82% of the world magnesium, all by thermal reduction of dolomite with ferrosilicon (Pidgeon process). In 2007, in other parts of the world, operating magnesium plants included: the U.S. with a single plant, US Magnesium LLC, at the Great Salt Lake in Utah; Israel had one plant, Dead Sea Magnesium; Russia had two plants; and Kazakhstan had one. These plants used the electrolytic reduction of magnesium chloride to produce magnesium metal. Brazil had one plant producing magnesium by the use of the modifi ed Bolzano (silicothermic) process (Table I). U.S.: US Magnesium LLC, Salt Lake City, is in the process of ramping up a 9,000 tpy expansion announced in September 2007 taking the plant to 52,000 mtpy and Figure1.NorskHydroÕsformerBecancourplantwasshutdownand is considering installing an additional 18,000 mtpy of sold in 2007. 60 LIGHT METAL AGE, APRIL 2008

107411_LMA_APR_2008.indd 60 2/22/08 7:08:50 PM egdYjXZgh! VcY '( bV\cZh^jb ^c\diopment XVhiZgh activity ^c in 8]^cV# many I]ZgZ areas lZgZof the Vahd automotive '' gZhZVgX] die ^chi^ijiZh casting VcYjc^kZgh^i^Zhd[[Zg^c\gZhZVgX]market. Volkswagen said in VcYSeptember iZX]c^XVa 2007 hjeedgi that by id 2012 i]Z 8]^cZhZit would bV\cZh^jb revive the plastic^cYjhign and Vh Vl]daZVcYXdcig^Wji^c\idi]Zmagnesium single-cylinder car XddeZgVi^kZthat would require J#H#"8VcVYV"8]^cV one liter of BV\cZh^jb;gdci:cYGZhZVgX]gas to travel 100 kilometers (the VcYequivalent 9ZkZadebZci of 238 miles B;:G9 per U.S. egd_ZXi#gallon). The car will only reach a maximum>cYZZY! speed Vh 9V_jc of 120 YZhXg^WZh!kilometer 8]^cV»hVjidbdi^kZVeea^XVi^dchper hour (75 mph). d[bV\cZh^jbVgZZmiZch^kZ#;dg ZmVbeaZ!magnesium-aluminum i]Z H]Vc\]V^ engine 6jid" bdi^kZblock developed >cYjhign by 8dgedgVi^dc BMW was H6>8available VhhZbWaZh in all BMW KL VcY cars engines are [dghigh i]Z tech, \ZVg with Wdm magnesium VcY XdkZg used ^c i]ZKLcrankshaft, ;^\jgZ all *! in VcY the i]Zinterests ^chigjbZci of keeping eVcZa down [dg engine

Zkdaji^dcd[8]^cV»hbV\cZh^jbegdYjXihigjXijgZ[gdbV bV_dgeg^bVgnegdYjXZgidV]^\]kVajZ"VYYZYegdYjXZg# >c'%%+!]ZcdiZh!i]ZgZlZgZVWdji.%bV\cZh^jbVaadn Y^ZXVhiZgh!bdgZi]Vc(%bV\cZh^jbh]ZZiVcYegdÃaZ total world production of magnesium is estimated to be 757,500 mt in 2007, an increase of approximately 15% from the 707,500 mt produced in 2006. This is a record China again produced about 82% of the world magnesium, all by thermal reduction of dolomite with Figure 4. Magnesium gear box and cover for SAIC’s Gol and Santana ferrosilicon (Pidgeon process). In 2007, in other parts of VW models.6 the world, operating magnesium plants included: the U.S. with a single plant, US Magnesium LLC, at the Great Salt Lake in Utah; Israel had one plant, Dead Sea Magnesium; Russia had two plants; and Kazakhstan had one. These plants used the electrolytic reduction of magnesium chloride to produce magnesium metal. Brazil had one plant producing magnesium by the use of the modiﬁ ed US Magnesium LLC, Salt Lake City, is in the process of ramping up a 9,000 tpy expansion announced in September 2007 taking the plant to 52,000 mtpy and Figure 2. Norsk Hydro’s Bécancour magnesium plant was shut down and sold in 2007. 2

Figure 5. Magnesium air pedal bracket for SAIC’s Buick Regal for GM.6

Figure 3. Comparison of price variations of magnesium, aluminum, Figure 6. Magnesium instrument panel for SAIC’s Cadillac STS for and zinc (London Metal Exchange 2007).4 GM.6 3 Conference Review, Part II 2007 China Mg & Automotive Conference By Dajun Chen, Contributing Editor Editor’s Note: This is a continuation of the review article “2007 China Mg & Automotive Conference, Part I” which appeared in the October 2007 issue of Light Metal Age. New Development in China lthough China’s magnesium and automobile industries started much later compared to North America, Europe, and Japan, the development of both industries has been very rapid over the lastA 10 to 15 years. Research and development in the application of magnesium and its alloys in automobiles has achieved remarkable progress, and magnesium applications in automobiles and motorcycles have expanded steadily. The Chinese government has supported the application of magnesium in the automobile industry for many years. Starting in 2001, the Ministry of Science and Tech- nology allocated special funds to support a “research and development of magnesium alloys and the commercialization of magnesium applications” program. In the Figure 2. Magnesium air pedal bracket for SAICÕs Buick Regal for Tenth National Five-Year-Plan (2001-2005), “Magnesium GM. Alloy Application Development” had been listed as a special program by the Chinese government, under which the “Magnesium Alloy Part Production and Application for Vehicles” was listed as a sub-program. In China’s New Eleventh Five-Year-Plan, this sub-program is still the most important part of the national science and technology Magnesium Research in Australia plan. Industrial Application: China’s magnesium applications %\-RKQ*UDQGÀHOG*UDQGÀHOG7HFKQRORJ\3W\/WG in automobiles began in the 1980s when the Shanghai Figure 3. Magnesium instrument panel for SAICÕs Cadillac STS for Automotive Industry Corporation (SAIC) started using GM.I]Z ;^ghi 6jidbdi^kZ Team Ldg`h Australia ;6L d[ 8]^cV jiâôZh magnesium die castings for the upper and lower blocks bV\cZh^jb Y^Z XVhi^c\ ^c V kVg^Zin d[ Veea^XVi^dch# of transmission cases in its Santana manufactured for VW. sameCdiVWan! castingustralian ;6L]Vh properties groups gZXZcian as researchingAZ91 jhZY Vbut B\"GZ much magnesium Vaadn better i]Vi heat- face ]Vh Since then, SAIC has used many magnesium die castings creepi]Z hVbZ resistance,considerable XVhi^c\ to egdeZgi^Zh the challenges production Vh 6O.& with of Wji its the bjX] large demise power WZiiZg of on different vehicles. For example, the gear box and its dieselXgZZegZh^hiVcXZ^ci]ZegdYjXi^dcd[bV\cZh^jbZc\^cZ enginesAustralian in the smelter engine projects covers (Figure and production 4). A high of cover for the VW Gol and Santana (Figure 1), air brake performanceXdkZgh[dgV&#(a$**`LY^ZhZaZc\^cZ[dgîhI^Vc_^c";6Lonly engine, small tonnages TA1 (1.3L, of local50 – 55KW), magnesium with three parts. pedal bracket for the GM Buick Regal (Figure 2), and magnesiumAHowever, magnesium alloy parts, research was successfully in Australia developed remains very by eVhhZc\ZgVjidbdWâZ;^\jgZ,# instrument panel for GM’s Cadillac STS (Figure 3). active and there is reasonable potential for long term growth in automotive use of magnesium due to its light weight and increasing social and regulatory pressures for fuel economy. The full value chain from magnesium metal production, through alloy development, new casting processes (Figure 1), automotive and electronic applications, to joining, and surface Ã nishing is covered. I]Z ¸IZVb 6jhigVa^V¹ Z[[dgi ^h X]VgVXiZgôZY Wn higdc\ industry and government support, a culture of close coordination, collaboration, and intermeshing between CSIRO, the Australian national research agency of 6,000 people (www.csiro.au), CAST Cooperative Research Centre (cast.crccentric.com.au), AutoCRC (www.autocrc. Figurecom), 4.7. and Mg-REMg-RE the magnesium Australiandie cast engine engine Research cover cover for onCouncil FAW’s FAW largehigh (ARC) powerperformance Centre diesel 6 Figure 1. Magnesium gear box and cover forSAICÕs Gol and Santana engine.dieselof Excellence engine. in Design of Light Metals (CEDLM) (www. Figure 9. 1. Twin-roll (L-R) Peter cast KeanAZ31 andcoils Daniel of magnesium East examine sheet ( 3 twin-toll50 mm wide cast AZ31 coils of magnesium sheet (width: 350 mm and thickness:9 3 mm) for VW. arclightmetals.org.au).Lî] hdbZ .% 8]^cZhZ Nine bV\cZh^jb universities Vaadn are Y^Z involved XVhiZgh and 3 mmmagnesium thick) being powder examined metallurgy at CSIRO’s including pilot equal plant. channel conventional slab casting and rolling limits its application. FAW (Figure 5) and has been installed in its Tianjin-FAW atCSIROÕspilotplant. deZgVi^c\idYVn!i]ZhZVgZ_jhiV[Zld[i]ZbVcn8]^cZhZwith CAST, AutoCRC, and CEDLM. Magnesium research 6jhigVa^Vcextrusion cVi^dcVa of magnesium gZhZVgX] powders. V\ZcXn! VcY jc^kZghî^ZhTwin roll casting (TRC) allows sheet to be produced The research and application of magnesium at First Au- passengerVjidbdi^kZis also conducted car. bV\cZh^jb Since then, at the XdbedcZciha number universities of WZ^c\magnesium outside egdYjXZY thesecast- Deakin University, and CSIRO are conducting researchclose in to Ã nal gauge and the amount of costly rolling tomobile Works (FAW) started in 1998. During the Tenth ings, such as engine cylinder cover cap, steering wheel, VgZXdbbZcYVWaZ!VcYbVcnd[i]Z^gVX]^ZkZbZcih]VkZCasting Process Technology and reheating, energy, and greenhouse emissions are [dg8]^cV»hYdbZhi^XbVg`Zi#6h9V_jccdiZh!¸GD]VhVYkVcXZYi]ZhiViZd[i]ZVgi^cil^cgdaa egdk^YZg!CSIRO aVg\Zhilaunched bV\cZh^jb the Light bVg`Zi! Metals VcYFlagship i]Z (LMF)aVg\Zhi XVhi^c\d[bV\cZh^jbh]ZZiomy, andYZbdchigViZY safety performance dc I"BV\ V and cZl has XVhi^c\ communication egdXZhh sector (cell phones, lap tops, cameras) is already using “Expanded Application of Magnesium in FAW Vehicles,” rearprogram fork, and to develop so on, have large been scale used transformational on its different vehi- tech- developed under the CSIRO LMF program (Figure 5). T- Mg sheet at around a few hundred tonnes per annum VjidbdWâZbVcj[VXijgZg^ci]ZldgaY!8]^cV]Vhjc^fjZ links8H>GD^hjh^c\XVgWdi]Zgb^XgZYjXi^dcd[bV\cZh^jb toMag CEDLM, is a gravity CAST, permanent and mold CSIRO low pressureLMF programs. integrated and this is seen as a fertile area for further Mg sheet and conducted a lot of research on magnesium materi- cles.VYkVciV\Zhnology FAW projects has ^c laid YZkZade^c\ to a reducesolid foundation Vjidbdi^kZ the cost andfor Veea^XVi^dch the environmental larger scale VcY CEDLM openedd in April 2006 to investigate the devel- als, processes, and applications. FAW founded a magne- application of magnesium in automobiles for the future. VidkZg&!+%%magnesium8idbZZihig^c\ZciZck^gdcbZciVagZfj^gZ" melting and die casting process. The high take up. The automotive use of magnesium sheet has lâaa^`ZanbV`Z^bedgiVciXdcig^Wji^dchidi]ZldgaY^cimpact of production and enable new industries in bZcihopmentquality, of high aluminum, yield (95%), magnesium, and low cover gas and requirements titanium lightcommenced with inner door panels being manufactured. sium die casting base with an annual production capacity Vjidbdi^kZa^\]ilZ^\]i^c\#¹Australia.Dong Feng The Motor $A34 (DFM) million is one per of annum the three LMF largest program au- alloys ofand T-Mag light allowhybrid opportunities materials. inThe high budget integrity is more auto thanThe growth prospects for automotive sheet are heralded 8H>GD^hV_d^cikZcijgZeVgicZg^ci]ZXdbbZgX^Va"applications such as engine blocks, cross members, and in the U.S. by USAMP and USCAR consortia and in of 1,500 mtpy. It also applied a new magnesium alloy with tomobilecoversLgdj\]i aluminum, manufacturers bV\cZh^jb magnesium($A3.7 in Veea^XVi^dchChina. It was million founded VgZ Vahdand in 14 WZ^c\1969 full $A21 million for the 2006--2010IB period, with $A15 million the addition of RE (rare earth) elements, which has the as the backbone enterprise of China’s automobile indus- ôVi^dcmotorcycle d[ i]Z swing I"BV\ arms. T-Mag adl egZhhjgZ needs no applied eZgbVcZci pressure bdaYEurope by individual OEMs and organizations. CSIRO ZmiZch^kZanejghjZY^c8]^cV#>c'%%+!i]ZgZlZgZVWdjitime equivalent personnel), and titanium production and XVhi^c\from theor vacuum egdXZhh federal to Ãgovernment [dgll the ]^\]die. The ^ciZ\gîn dievia Ã ARC,lls smoothly bV\cZh^jbthe balance from the from Vaadnmaterial has been supplied for evaluation to one of these processing. CSIRO plays a crucial role in providing large* the Victorianbottom, minimizing government, turbulence, and the oxide universities generation, (Monash and egd\gVbh#I]Z8H>GD»hIG8egd\gVb]VhWZZcgjcc^c\ 36 (% 8]^cZhZ bV\cZh^jb LIGHT METAL h]ZZi AGE, VcY egdÃaZDECEMBER egdYjXZgh# 2007 XVhi^c\h;^\jgZ&% Lgdj\]iscale casting bV\cZh^jb facilities to Vaadnh conduct ^c i]Zalloy [dgb development d[ h]ZZi work VcY University,gas entrapment University in the of casting. Queensland, Deakin University,since 2001 and the pilot plant can produce up to 600 mm Zmigjh^dchlâaWZjhZYVadc\lî]XVhi^c\h^ci]ZB;:G9and new casting process development in collaboration the University of New South Wales, the Universitywide, of 3 mm thick sheet in 100 kg coils. Coils have been i] supplied to several market segments for evaluation and egd_ZXi!with the universities, Vh YZhXg^WZY CAST, Wn 6aVc and AjdCEDLM. d[ C86IZX]C86]Vh 6jhigVa^V»h bV\cZh^jb gZhZVgX] Y^gZXi^dch ]VkZ WZZcHowever, as a result of other company considerations, WZZcrunning egdYjX^c\ since 1990.6O(& Zmigjh^dch The intent VcY is h]ZZi to strengthen;^\jgZ - well informed by in-depth industry analysis withinMIL chose not to exercise the option. CSIRO continues [gdbi]Z^g98XVhiWâaZiVcYhaVW#collaborative research ties between- industry (contributing the research institutions but also with assistance fromto actively pursue commercialization opportunities for its dkZg 6' Wâa^dc id YViZ VcY gZhZVgX] dg\VcôVi^dch# Australian Ãgb8aVg`BVggdcEinAiY#l]^X]]VhWZZcpatented technology. I]Z egd\gVb»h dW_ZXi^kZ ^h ¸Id Zc]VcXZ 6jhigVa^V»h In addition, T-Mag and TRC, CSIRO, and University providing the magnesium industry analysis since 1998.of Queensland researchers in CAST have developed industrial, commercial, and economic growth through AirCAST, a new direct chill hot top casting mold, capable the development of sustained, user-driven, cooperative Metal Production of producing magnesium extrusion billets with excellent public-private research centers that achieve high levels surface quality that do not require scalping (Figure 6). d[djiXdbZh^cVYdei^dcVcYXdbbZgX^VaôVi^dc!¹ i.e. the The technology has been licensed exclusively to CAST Australia has high quality magnesium ore bodies.industry partner o.d.t. Engineering and is installed at a intent is technology transfer for the good of the country. However, with the closure of many Western magnesiumTaiwanese research institute. CAST has funding of more than $A100 million over producers and winding up of proposed smelter projects, seven years until 2012. Founded in 1993, CAST like due to low cost Pidgeon process production in China, Corrosion and Coating Technology bdhiXddeZgVi^kZgZhZVgX]XZciZghdeZgViZhVhV¸k^gijVa¹ CSIRO is looking at developing a new low cost processCEDLM is working on basic scientiÃ c understanding of dg\VcôVi^dclî]Y^heZghZYcdYZhViÃ ve universities and using carbothermic reduction of magnesium at overthe factors controlling Mg corrosion in intermittent salt at the CSIRO laboratories in Victoria and Queensland. 1600°C that meets stringent environmental conditions.spray as applicable to auto applications with Mg coupled FigureCSIRO 8. Samples is a founding of WINCA’s partner AX31 extrusion of CAST billet andand rolled conducts sheet The challenge is how to achieve rapid cooling of to the steel, and development of alloys with controlled madeVabdhi]Va[d[86HI»hG9!l]âZ from cast slab.8 Ã ve universities conduct electrochemical properties for aqueous corrosion re- magnesium vapor without back reaction with the carbonsistance. theBV\cZh^jb remaining GZhZVgX] work (Monash ^c 6jhigVa^V/ University,7Zh^YZh University i]Z @dgZVc of Y^dm^YZ#JhZd[VhjeZghdc^XcdooaZ^hjcYZg^ckZhi^\Vi^dc#Under the LMF, CSIRO has allocated $A2.1 million over Queensland, Deakin University, Swinburne University, and The CSIRO team has demonstrated the basic concept threefor years for collaboration between CSIRO and CAST, EdhXdkZcijgZ!il^cgdaaXVhi^c\d[bV\cZh^jbVaadnh^hVahd Figure 1Figure0. T-Mag 5. T-Mag cast cast magnesium wheel at CSIRO. wheel at CSIRO.9 WZ^c\YZkZadeZY^c6jhigVa^V;^\jgZ.VhlVhgZedgiZYCentral Queensland University). Australian Magnesium, the process in the laboratory and is working on improvingand CEDLM to work on automotive lightweighting and now Advanced Magnesium Technologies (AMT), is a. cost-effective titanium products from powder precursors. Wn9g#?d]cc]^hgZk^Zld[i]ZegZhZcihiVijhd[bV\cZh^jbgZhZVgX]founding industry participant in CAST and has supported partneringI]ZJH86GXdVaî^dcd[8]gnhaZg!;dgY!VcYcAutoCRC heîZ d[ cooperative i]Z X]VaaZc\Zh! research GD9ZeVgibZcid[>cYjhignhV^Y!¸L]Vi»hhdZmXî^c\VWdji VcY 86HI gZhZVgX]Zgh ]VkZ YZkZadeZY 6^g" Vbdc\6jhigVa^Vc\dkZgcbZciV\ZcX^Zh!^cYjhign!8H>GD 86HI!Vthis cZlinnovative Y^gZXi technology X]âa ]di is its ide potential XVhi^c\ for bdaYuse in the [dg egd" car industry both here and abroad, and the ability to 107411_LMA_APR_2008.indd 56 gZYjXZ\gZZc]djhZ\VhZb^hh^dch#¹I"BV\YZkZadebZci 2/25/08 4:46:59 PM 4 ]Vh iV`Zc eaVXZ lî]^c 8H>GD»h bV_dg XVhi^c\ XZciZg that houses twin roll casting, low and high pressure die casting, and remelt ingot conveyor casting. The Australian Die Casting Association is a member of CAST and has received technical support on magnesium high pressure die casting from CAST for the production of magnesium steering wheels and other components. Figure 6. As-cast AZ31 direct chill cast extrusion billet surface using The high price of magnesium sheet produced by As-cast hot top mold. 58 LIGHT METAL AGE, APRIL 2008

107411_LMA_APR_2008.indd 58 2/27/08 11:22:30 AM OCT 2005#8 10/10/05 12:26 PM Page 28

YjX^c\bV\cZh^jbVaadnZmigjh^dcWâaZihlî]ZmXZaaZci The Z06 aluminum spaceframe design (Figure 3) was hjg[VXZfjVaîn a collaborative effort consisting of design engineers from CdkZa Vci^"Xdggdh^dc XdVi^c\h ]VkZ WZZc YZkZadeZY GM, Alcoa, and Dana Corporation. Dana Corporation [dgbV\cZh^jbl]ZZah^cVXdaaVWdgVi^kZegd_ZXiaZYWn leveraged Alcoa’s experience and proven capabilities in 86HI aluminum spaceframe design with the Audi A8 and 8dch^YZgVWaZ ZmeZgi^hZ ]Vh WZZc VX]^ZkZY ^c i]Z other aluminum intensive automobiles while adding new Veea^XVi^dch d[ hZa[ e^ZgX^c\ g^kZih VcY aVhZg lZaY^c\ d[ MIG welding technology, laser welding, self-pierce rivet- bV\cZh^jbVaadnXdbedcZcih ing (SPR), and full spaceframe machining (Figure 4 a, b, c) to assemble and fabricate the Z06 aluminum space- EgZhZci HîjVi^dc ^c Gjhh^V/ >c gZedgi^c\ dc i]Z 'cY frame from 6xxx extrusions, 5xxx sheet panels, and A356 Gjhh^Vc BV\cZh^jb ¶ 7gdVY =dgôdch bZZi^c\ ]ZaY permanent mold castings. The longitudinal rails sup- ^c Hi# EZiZghWjg\ ^c ?jcZ '%%,! 7dW 7gdlc gZk^ZlZY plied to Dana for fabrication were hydroformed and i]Z egZhZci egdYjXi^dc hiVijh Vi i]Z bV^c bV\cZh^jb hydropierced at GM’s Metal Fabrication Division. egdYjXZgh ^c Gjhh^V! Hda^`Vbh` BV\cZh^jb Ldg`h HB@ VcY 6k^hbV! l]ZgZ idiVa bV\cZh^jb h]êbZcih [dg '%%, lZgZ Zhi^bViZY Vi '-!%%% bi! V YZXgZVhZ d[ s&%!%%% bi dkZg '%%+#&% 6k^hbV jhZh bV\cZh^jb bZiVa idgZVXilî]iîVc^jbiZigVX]adg^YZidegdYjXZiîVc^jb bZiVa#>c?jan'%%,!7dZ^c\hZijeV_d^cikZcijgZJgVa 7dZ^c\BVcj[VXijg^c\lî]i]ZldgaY»haVg\ZhiiîVc^jb %#/,! 4-%&!!'*!)21%.$%-!.$%*+!''!*"2Figure 11. GM’s Mike Meloeny and Lisabeth Riopelle (Hydro) ,*-$*1 showing %)#.$!*,0!..! (#)!-%/(!)#%)! ,the Corvette Z06 engine cradle that was high '! pressure die cast by egdYjXZg! Gjhh^V»h KHBED"6k^hbV! id bV`Z iîVc^jb Meridian Technologies from Hydro alloy AE44 at a 35% weight saving XdbedcZcih[dg7dZ^c\»hcZl,-,eVhhZc\ZgV^gXgV[i# over the aluminum casting.4 7dW Vahd gZedgiZY dc i]Z &hi Gjhh^Vc BV\cZh^jb ¶ in the front and back suspension, cast aluminum block a. 7gdVY=dgôdchbZZi^c\]ZaY^cBdhXdl^cCdkZbWZg$ andY^Z XVhi^c\hhead in [dgthe i]Znew hiZZg^c\ 6.0-L V-8 l]ZZa! L52 engine, eZYVah! magnesium VcY bVhiZg 9ZXZbWZg '%%*#&& 6i i]Vi Xdc[ZgZcXZ! hZkZgVa eVeZgh castingsXna^cYZghjeedgiVhlZaaVh&)I]^mdbdaYZYbV\cZh^jb used for the steering wheel, pedals, and master lZgZegZhZciZYYZiVâ^c\!Vbdc\di]Zgh!egdYjXi^dcYViV cylindereVgih^cXdgedgViZY^cidîhXdckZgi^WaZgdd[idehnhiZb# support, and the lightweight convertible top&) [gdb 8]^cV egZhZciZY Wn gZegZhZciVi^kZh d[ i]Z 8]^cV frameEgZhZcian!bV\cZh^jbgZegZhZcihVh^\c^ÃXVciedgi^dc and hardware made of Thixomolded® magne- BV\cZh^jb 6hhdX^Vi^dc! gZhZVgX] VcY YZkZadebZci sium.d[i]Za^\]ilZ^\]ibZiVahegd_ZXihlî]^ci]Z;gZZYdb86G There are 14 structural and cosmetic thixomolded d[ bV\cZh^jb Vaadnh ^c @dgZV! i]Z gZXZci egd\gZhh magnesiumegd\gVb! l]dhZ parts incorporated \dVa ^h id VX]^ZkZ into the i]Z Z06 ]^\] convertible kdajbZ bVYZ^cXgZZegZh^hiVcibV\cZh^jbVaadnhWn9ZVYHZV roofegdYjXi^dc top system d[ made Vjidbdi^kZ by Car kZ]^XaZhTop Systems. i]Vi! During XdbeVgZY SAE Sadkov.BV\cZh^jbBG>hZg^Zhd[bV\cZh^jbVaadnh!il^cgdaa The design and use of magnesium in Tupolev 2005,competitivelî] Thixomat '%%' material egdYjXZY hosted costs an kZ]^XaZh! (includingopen house ]VkZ recycling at i]Zits Ann costs [daadl^c\ Arbor and aircraftXVhi^c\$gdaa^c\ was thoroughly d[ bV\cZh^jb explored. h]ZZi Use jeof magnesium id '!%%% bb in TechnicaltheX]VgVXiZg^hi^Xh/ recycling Development of as many Center residual showing materials these as andpossible). other civilian aircraft production has decreased over the past developmentsIt is an urgent in task automotive of the magnesium applications industry of its and Thixo- all l^YZ VcY %#** bb i]^X` Wn I]nhhZc@gjee HiV]a 6ci]ZaViiZgeVeZg!bV\cZh^jb to 5% of the aircraft weight. Charts were lightrequirement,9jZidi]Z^beVXii]VibV\cZh^jbXVc]VkZ^cVX]^Zk^c\ metals industry, and that its the new chemical all-aluminum composition spaceframe and presentedjhV\Z^cIjedaZkV^gXgV[ilVhYdXjbZciZYIVWaZ>>># covering both civil and military aircraft. chassispurityi]ZhZ\dVah!hZkZgVaegd_ZXih]VkZWZZc[jcYZYhiVgi^c\^c ofand the cast recycled magnesium material front mustcrossmember. be of the All same the papersstandard'%%%i]gdj\]'%&%VheVgid[i]Z6jidbdi^kZBV\cZh^jb presented of quality at as SAE primary 2005 onalloys. the Corvette Z06, along with'%'%The papers eaVc!many ejWa^h]ZY problems on the history inherent ^c CdkZbWZg of thein the Corvette, '%%+ recycling Vh BV\cZh^jb were industry pub- lishedwereK^h^dc reviewed.in '%'%/ a Corvette V Cdgi] Presently, retrospective 6bZg^XVc Class 6jidbdi^kZ book. 1 scrap1 Individual HigViZ\^X (clean gates,K^h^dc SAE 2005runners,[dg BV\cZh^jb papers and on biscuits VkVâVWaZthe Z06 from aluminum dc the i]Z die JH86G spaceframe casting lZWhîZ/ process) and mag- lll# is nesiumthejhXVg#dg\! main front source l]^X] crossmember for iVg\ZiZY magnesium V are \gdli] also recycling available, d[ bV\cZh^jb via as melting refer- ^c enced.andCdgi]6bZg^XVcVjidbdi^kZkZ]^XaZh[gdb&&"&(aW*"+ refi ning in order to produce material with the same c. properties`\idYVnidbdgZi]Vc((%aW&*%`\eZgkZ]^XaZWnZ06 Aluminum as the Spaceframe: original alloy.In designing The main the problem Z06 alu- in %#/,! -!,1!' %)# !'',**.% !'') ( $%)%)# !'' minumrecycling'%'%# EZg]Veh spaceframe, material i]Z other i]gZZ the design thanbdhi Classegdb^cZci team 1at is GM detrimental bV\cZh^jb was chal- /-! %) '/(%)/( -+ !",(! --!('2 . ) !+,%).! lengedimpurities to that maintain cannot the be structuraleliminated performance during melting of and the 1%.$ +!,(%--%*) ",*( +!, 3 egd_ZXih edgi[da^d lî]^c i]Z ;gZZYdb86G egd\gVb ).!,).%*)' Corvettehave^ckdakZXVhi^c\egd_ZXih/i]ZBV\cZh^jbEdlZgigV^c8Vhi to be C5, diluted the predecessor by adding ofclean the Z06primary built magnesium, with a steel spaceframe,which8dbedcZcih is expensive. while ;^\jgZ reducing &'! the =^\] spaceframe >ciZ\gîn weight BV\cZh^jb by at The Z06 represents a milestone in the history of the least6jidbdi^kZAs recycling30%. This 8Vhi^c\h! laws was become accomplished VcY more JaigV"aVg\Z comprehensive, with the 8Vhi^c\h Z06 alu- the [dg Corvette, as it is the first Corvette built on an all-alu- minumgoalA^\]ilZ^\]iKZ]^XaZHigjXijgZh;^\jgZ&(# will spaceframe. be to recycle1-3 95% of the materials used in cars minum body structure. The annual requirement for the by 2015. Recycling of magnesium chips, turnings, and Table I.III. Magnesium Magnesium usage usage in in Tupolev Tupolev aircraft. civilian and military aircraft.11 Corvette Z06 is estimated at 7,000 units. The aluminum other types of scrap is much more diffi cult if the original spaceframe utilizes 6061-T6 and 6063-T6 and -T5 alu- alloy composition must be met. In any of the existing 6jidbdi^kZ BV\cZh^jb ^c Cdgi] 6bZg^XV/ GZXZci minum extrusions (54 wt.%), 5754-O sheet stampings refi ning processes, both dross and sludge are created. (36 wt.%), and A356-T6 permanent mold castings (10 Vjidbdi^kZAutomotive bV\cZh^jb Magnesium YZkZadebZcih Recycling by VcY Gunter Veea^XVi^dch Franke While dross blocks can be recycled, the process is slow and ^cCdgi]6bZg^XV]VkZWZZcZmiZch^kZanXdkZgZY^cAB6# wt.%). To assemble these components, Dana utilizes new of,!&'"&+ Norsk Hydro Magnesiumgesellschaft GmbH, Bottrop, the product does not always meet specifi cations for die TransSynergic MIG welding equipment with SynchroPuls Germany, was presented by Christoph Schendera of casting, thus it is used in aluminum alloying or production >cVhhZhh^c\i]ZVjidbdi^kZa^\]ilZ^\]i^c\egd_ZXihd[ technology to join most of the components together, Norsk Hydro. It was pointed out in the introduction of desulfurization material. Sludge is much more although laser welding is used to improve structural thati]ZJ#H#8djcXâ[dg6jidbdi^kZGZhZVgX]JH86GVcY magnesium recycling today is a complex issue. diffi cult to recycle and there are no facilities in Germany J#H#6jidbdi^kZBViZg^VahEVgicZgh]êJH6BE!AB6 integrity and sealing in the tunnel subassembly, while Recycling involves everybody. Society wants a safe that do this. Magnesium sludge is extensively disposed of self-piercing rivets join many of the aluminum stamp- and]VhYdXjbZciZYi]ZXgî^XVa^bedgiVcXZd[bV\cZh^jb clean environment, consumers want inexpensive at dumping grounds—if possible—and partially even in id i]Z dkZgVaa ;gZZYdb86G egd\gVb i]Vi ^h hedchdgZY ings. These joining techniques compare with spot weld- products of reasonable durability and re-usability (Life dumping sites below ground at considerable expense. ing that was used exclusively on the C5 steel construc- Cycle^caVg\ZeVgiWni]ZJ#H#9ZeVgibZcid[:cZg\n9D: Economics), and customers, the die casters, need Norsk Hydro, Almamet, and GSES have formed a joint VcY l]^X] \gZl dji d[ i]Z [dgbZg EVgicZgh]ê [dg V tion. The completed Z06 assembly is then machined to CZl

Free Exhibits Free Social Hour & Reception • Reduces heat-up

Visit intlmag.org or contact IMA time without overheating coil edges at [email protected] for details! • Reduces local cracking of residual surface oil • Enhances efﬁ cient oil evaporation

Figure 5. Bob Powell and Joy A. Hines display the magnesium cylinder • Reduces the variation in the material block developed on Project AMD 304. properties of processed coils Plans for the recently formed project AMD 601 – High Integrity Magnesium Automotive Components (HIMAC) • Reduces discoloration of strip edges in – were presented by Bruce Cox of DCX. The goal of this 5xxx and 7xxx alloys project is to make Al casting methods, including low-pressure permanent mold, squeeze casting, and ablation cast- • Produces higher volume jet ﬂ ows with Sponsored by the International ing (a newly-developed, high-integrity sand casting process) Magnesium Association suitable for Mg and to cast several Mg alloy control arms. reduced fan motor power using Enabling technologies to control mold filling, optimize www.intlmag.org metallurgical structure and performance, and reduce cost comparatively lower fan speeds will be investigated. Automotive Aluminum Project Review: Eric McCarty of DCX • Improves temperature uniformity throughout LIGHT METAL AGE, FEBRUARY 2006 61 presented the results obtained on project AMD 405 – Im- the coil during the heating cycle proved Automotive Suspension Components Cast with B206 Alloy. The B206 alloy is a new Al-Cu casting alloy with tensile properties in appropriate tempers that match those of fer- )(%LQGG ritic ductile iron, commonly used in these components. 30 Other automotive aluminum projects are applicable to both aluminum and magnesium automotive components: project AMD 406 – Ultra-Large Casting for Lightweight Vehicle Structures – and project AMD 407 – Die Cast Net- Shaped Hole Process Development in Aluminum and Mag- nesium (for Thread Forming Fasteners). Automotive Titanium Project Review: Due to the high cost of titanium, two titanium projects are directed at lowering the

cost of automotive titanium components: •Project AMD 310 – Low Cost Powder Metallurgy Tech- SECO/WARWICK Corp. SECO/WARWICK Ltd. nology for Particle Reinforced Ti Components, aimed at PO Box 908 180 Mercer Street Sobieskiego 8 production of high performance connecting rods Meadville, PA 16335-6908 USA 66-200 Swiebodzin, Poland •Pacific Northwest National Laboratory (PNNL) project Phone: +1 814-332-8400 Phone: +48 68-3820-500 – Low Cost Titanium Powder for Feedstock, aimed at using Fax: +1 814-724-1407 Fax: +48 68-3820-555 E-mail: [email protected] E-mail: [email protected] TiCl4 feedstock www.secowarwick.com www.secowarwick.com.pl Editor’s Note: Additional information on USCAR, USAMP, and the FreedomCAR and Fuel Partnership is available on the USCAR website, www.uscar.org. LIGHT METAL AGE, OCTOBER 2006 37

102161_LMA_OCT_2006.2.indd 37 10/6/06 3:18:06 PM JUN 2005#6 6/14/05 4:23 PM Page 38

the same time, the North American automotive industry ment center, reviewed the status of the USAMP MPCC has established several automotive magnesium R&D pro- project in his lead presentation for the IMA automotive grams supported by the U.S. Council for Automotive seminar, The USAMP Magnesium Powertrain Cast Research (USCAR), the U.S. Automotive Materials Components Project. Tremendous progress has taken Partnership (USAMP), and the U.S. Department of place since Powell presented the case for magnesium in Energy. USCAR and USAMP are umbrella organizations his earlier presentation at the IMA 2003 meeting in of DaimlerChrysler Corporation, Ford Motor Company, Stuttgart. The readiness of magnesium to be a structural and General Motors that were formed in the early 1990s material for powertrain applications appears at hand. to further strengthen the technology base of the U.S. Powell indicated that sometime in 2005 the USAMP automotive industry through cooperative, precompeti- MPCC project team will assemble and conduct dyna- tive research. mometer tests on magnesium intensive Duratec 2.5L V6 These magnesium casting programs involve teams of engines running with a traditional ethylene glycol base researchers from these auto makers and various North coolant. The magnesium industry has a lot riding on the American companies and organizations, which have as outcome. their overall objective the determination of the technical Creep Resistant Magnesium Alloys: To withstand the high feasibility and cost-benefit ratio of potential innovations operating temperatures (150-175°C) in these powertrain in light weight magnesium chassis, interior, and body applications, alternatives have been developed by mag- components. nesium and automotive companies to the commercial Magnesium has proven to be up to the task. A magne- AM60, AM50, and AZ91 magnesium alloys. Two presen- sium engine cradle, developed by Meridian Technolo- tations on creep resistant magnesium alloys were made at gies in Ontario, Canada, was on display at the Hydro the IMA automotive seminar: DaimlerChrysler’s High Magnesium booth. The component is in production for Temperature (Creep Resistant) Magnesium Alloy the new Corvette Z06 (Figure 2). Production of magne- Development by Randy Beales of DaimlerChrysler, and Optimization of Die Casting Process and Performance of Creep Resistant Alloys MRI153M and MRI1230D by Nick Fantetti of Dead Sea Magnesium. Like some of the other automobile companies, DaimlerChrysler is developing their version of a creep resistant magnesium alloy, called DCX, mainly to control cost, as rare earths and alkaline earth elements are often used in alloying magnesium to impart creep resistance. The DCX alloy of Daimler- Chrysler contains aluminum and calcium as alloying elements. The MRI153M and MRI1230D alloys of Dead Sea Magnesium have moderate and high heat resistance, respectively, and have found applications in production of automotive gearboxes, oil pans, oil pumps, and crankcases. In his presentation, Fantetti addressed the importance of tailoring die casting parameters (molten metal and die temperatures, injection profile, filling and dwell time, and lubrication) to these new alloys to opti- Figure 2. Magnesium engine cradle in production for the new Corvette mize properties. Z06. sium intensive engines is gaining, as evidenced by BMW’s Wrought Magnesium in Automotive Applications new six-cylinder magnesium/aluminum composite crankcase used as part of its NG6 inline six-cylinder As in previous IMA automotive seminars, it appears that engine (Figure 3). wrought magnesium is taking a back seat to cast magnesium within the automotive industry, not only in North and G-Mag International Ontario, Canada, endeavored to America but also in Europe and Asia. This did not stop replace the conventional multi-piece steel structure that Magnesium Elektron in their exhibition booth from pro- forms the inner front fender (the shotgun) with a single moting the benefits of wrought magnesium in such auto- magnesium casting. The existing F-150 radiator support is motive applications as forged wheels made of ZK60A, manufactured by the High Pressure Die-Casting (HPDC) superplastic formed AZ31B sheet in integrated mono- process. HPDC is a desirable manufacturing process coque construction, and extruded bars and sections from from an industry perspective but has shortcomings when their WE54, WE43, ZW3, AZM, and AZ80 magnesium used to produce certain parts. The main problem is the alloys. Superform USA, which has provided the automo- presence of porosity in HPDCs, which have a detrimental bile industry with various superplastically formed alu- effect on mechanical properties. Thixomolding is an minum parts, is now working with Magnesium Elektron alternative to HPDC that offers higher ductility with high to promote superplastically formed magnesium parts. strength and low wall thickness in magnesium castings. Figure 13. The “shotgun” structural AM60 magnesium member Historically, thixomolding has been limited to relatively Magnesium at SAE 2005 producedasademonstrationpartbyamodiÞedthixocastingprocessFigure 4. Shotgun structural member produced by a modiÞ ed thixo- small parts. However, by incorporating multiple drop connectingtheA-pillar(Þrewall)totheradiatorsupportonaFordF-molding process. hot runner technology developed by Husky Injection Automotive magnesium seems to be a hot topic not 150 truck.16 Molding Systems, the thixomolding process was adapted Process Award only with IMA members but also with automotive engi- toFigure produce 3.14. Mg/Al Composite larger composite automotive Mg/Al crankcase crankcase structure for forthe theBMW parts, BMW NG6 such NG6 engine as inline the(cour- 6- neers. Magnesium sessions were prominently featured =dlgZVa^hi^X^hi]Z'%'%bV\cZh^jb\dVa4>cgZhedcY^c\ shotguncylindertesy: BMW engine. (Figure Group)15 . 4). Certain critical areas achieved less Product: “Shotgun” structural member which connects and well attended at SAE 2005, the annual conference of idi]^hfjZhi^dc^cDXidWZg'%%,![i]Z8]^cZhZYZX^YZidZbWVg`dcVbV_dgThe shotgun structural member was produced by basiclaboratory structure at theconsist General of a few Motors large research magnesium and castings develop- this year in Light Metal Age. YZbdchigVi^dc d[ bV\cZh^jb»h Vjidbdi^kZ gZaZkVcXZ as an alternative to many stamped steel or aluminum an enhanced thixomolding process with AM60 alloy. components. If this demonstration part is adopted by idResearch i]Z^g [jZa for egdWaZbh! this demonstration hVn Wn egdYjX^c\ part was Vc sponsored jaigVa^\]i! 38 LIGHT METAL AGE, JUNE 2005 aVg\Z!]^\]"eZgXZciV\ZbV\cZh^jbkZ]^XaZ[dgi]Z'%&%by the United States Automotive Materials Partnership the auto industry, it has the potential to use well over H]Vc\]V^ LdgaY»h ;V^g! i]Z gZhi d[ i]Z ldgaY lâa iV`Z 5,000 additional tons of magnesium per year. With its (USAMP) under the United States Council for lightweight and superior crashworthiness it is hoped that OCTcdi^XZ°l]nAutomotive 2005#8 10/10/05 Research cdi Wjn 1:11 (USCAR)i]Z PM Vjidbdi^kZ Page with 46 funding bV\cZh^jb from eVgih the i]Vii]Zn8]^cVlâaYZkZade!egdYjXZVcYZmedgi!Vi the shotgun will inspire the development of many new U.S. Department of energy as part of their Ultra-Large magnesium applications in the automotive industry. adlZgeg^XZhi]VclZXdjaY\Zii]Zb^cCdgi]6bZg^XV#¹Castings for Lightweight Vehicle Structures project (AMD406).>c 8VcVYV! i]Z 6JID'& cZildg` d[ XZciZgh d[ Editor’s Note: For more information on the winning entries and ZmXZaaZcXZ^hV8VcVY^VcVjidbdi^kZG9eVgicZgh]ê!Building on the success of the F-150 magnesium radiator the magnesium information resources, go to the IMA website: Figure 15. BMW NG6 engine (courtesy BMW AG).20 ZhiVWa^h]ZY^c'%%&!i]VihjeedgihVXVYZb^XVcY^cYjhig^Vasupport (an IMA award winner in 2003), Ford in the U.S. www.intlmag.org. All photos by John Lyon. XddeZgVi^dc dc kVg^djh Vjidbdi^kZ egd_ZXih# I]Z ild carsbV\cZh^jbegd_ZXihhjeedgiZYWn6JID'&VgZ/Lgdj\]i are expected to set the standard in terms of excel- lentBV\cZh^jb[dg6jidbdWâZhBXBVhiZgJc^kZghînVcYRequest performance, for Proposal: driving comfort, Magnesium and low fuel con-and/or Aluminum Casting Demonstration BV\cZh^jb8Vhi^c\EgdXZhhZh>>Jc^kZghînd[LZhiZgc sumption.&- To satisfy these requirements in the best possi- bleDciVg^d# The way, United it 8VcVY^VcgZhZVgX]aVWh!^cYjhig^VaeVgicZgh! was States necessary Automotive to design Materials a completely Partnership new (USAMP), a consortium of the United States Council for engineVcYAutomotive i]Z^g to replace hX^Zci^hih Research the VcY existing(USCAR) Zc\^cZZgh inline composed eVgi^XêViZ six-cylinder of DaimlerChrysler lî] spark- i]Z AG, Ford Motor Company, and General Motors ignitionJ#H#Corporation, VcY engine, 8]^cV is which seeking^c i]Z had B;:G9 preliminary been in egd\gVb! production proposals ]dlZkZg! for for about processes Vh capable of producing ultra-large casting (ULC) 15YZhXg^WZYegZk^djhanWn7dW7gdlcVcYc conduct XdkZg^c\ this i]Z demonstration. +'cY Conducted in tandem, one phase is designed to ingdemonstrate fuel consumption. a process Fundamentally that is capable newof producing technologies, a structural ULC component at a size consistent with existing such6ccjVa as the LdgaY composite BV\cZh^jb magnesium-aluminum 8dc[ZgZcXZ ]ZaY ^ccrankcase 7Zga^c! andilVh engine will take place at twokZgnCurrently, engine Ãii^c\ plants. [dg two i]Z processes bV\cZh^jb are under bZZi^c\ development id WZ ]ZaY and ^cdemonstration. The ULC team of USAMP is expanding its 7Zga^c! Vh 7Zga^c lVh i]Z bV^c XVeîVa d[ '(%9VcYBG>&*(B^cVkVg^Zind[Veea^XVi^dchvehicles are: half the mass, as affordable, more recyclable, up to 150°C. It was therefore necessary to select and Figureof simulation 17. Dead Sea and Magnesium by means displayed of testing,” the VW 4-cylinder the authors engine develop^cand i]Z^g of equal Zc\^cZan alloy or Veea^XVi^dchbetter to compromise quality id and gZeaVXZ betweendurability. Vajb^cjb the required Vaadn blockwrote, cast “BMW from MRI has 15 succeeded3M at the 18th inAnnual making Magnesium use of in the Automotive mate- mechanical6(-%;^\jgZ&,#LZ^\]ihVk^c\hXgZYîZYidgZeaVX^c\ properties, in particular, resistance to creep, Seminar.rial magnesium7 for the crankcases of modern engines fatigue,48 and castability. At the beginning of the project, with high specific performance.LIGHT METAL The AGE, set objectiveJUNE 2007 of a 6commercial alloys from different material suppliers were considerable reduction in the crankcase’s weight has investigated with regard to their mechanical properties thus been achieved. The breakthrough was made with and castability. The focus was on static, endurance, and the design of the composite crankcase based on an 104329_LMA_JUN_2007.inddcreep properties 48 in the target temperature range. The AlSi17 insert in a AJ62 magnesium housing (Figure 6/4/0710). 1:34:15 PM creep properties were assessed using multilevel tensile The basis of this successful development was an inten- tests with variation in both load and temperature form- sive, interdisciplinary cooperation along the process ing the basis for simple creep models used in the numer- chain between specialists and experts from a variety of ical FE analysis of the structure. In addition, bolt load BMW’s development units, external material suppliers retention (BLR) tests were performed on components. and the BMW light metal foundry in Landshut. Castability was evaluated on the basis of casting defects, hot cracking, and die sticking tendency. From this initial alloy screening the potential of the different alloy systems was evaluated, with the AJ (Mg-Al- Sr) ternary alloy system of Noranda showing the most promising potential with regard to design and manufacturing requirements. The initial AJ52x alloy was further developed with regard to improved castability. The first BMW crankcase article gives a very complete and detailed discussion of the alloy casting developments and its metallurgy. Production details and methods used to produce a dual-metal engine block along with pictures are included in the discussion. The authors concluded: “A careful balancing of the mechanical properties with emphasis on both creep and fatigue material properties next to the castability process capability was achieved with the alloy optimization as described above. With the introduction of the Mg-Al composite crankcase design in the new I6 engine, it is demonstrated that the AJ62A alloy has Figure 10. Closed-deck aluminum cylinder insert (AlSi17Cu4). the capability to sustain such a severe application. With arc spraying as surface treatment and an optimized tem- “The use of correct material data determined by perature controlling during the HPDC-casting process means of intensive testing in the computer simulation (Figure 9), it was possible to achieve stable bonding enabled a virtual concept selection and an optimization between aluminum and magnesium over a lifetime. A of the construction at a very early stage. The results of new testing methodology has been adapted for quality the computer simulations have been verified in compre- check purposes. With this ultrasonic lock-in thermogra- hensive tests. This has also made it possible to realize a phy, the processes in production can be controlled.” 46 LIGHT METAL AGE, OCTOBER 2005 6(-%lî]i]ZhZ9HBVaadnhlZgZ(("),YZeZcY^c\dc Veea^XVi^dch! VcY bV\cZh^jb ^ciZch^kZ kZ]^XaZh B>Kh Veea^XVi^dc#, bVn Yd i]Z hVbZ# :VgaZ YZkZadeZY ]^h ^ciZgZhi ^c CZl bV\cZh^jb YZkZadebZcih ^c :jgdeZ VgZ WZ^c\ Vjidbdi^kZbV\cZh^jbYjg^c\Vadc\gVX^c\XVgZZg#Cdl VYkVcXZY jcYZg i]Z jbWgZaaV d[ i]Z >ccdBV\IZX :VgaZ»h XdbeVcn! 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[djcYgn egVXi^XZh! XVhi^c\ YZh^\c eg^cXêaZh! hVcY XVhi^c\! Y^Z XVhi^c\! egdXZhh^c\ d[ XVhi^c\h [dg heZX^Va Veea^XVi^dch! m"gVn ^cheZXi^dc d[ XVhi^c\h! [djcYgn Xdhi VXXdjci^c\! bV\cZh^jbVaadncdbZcXaVijgZ![dg\^c\h!h]ZZi[dgb^c\! dg\Vc^X Ãc^h]Zh! XVi]dY^X egdiZXi^dc! bV\cZh^jb Ygn WViiZg^Zh!VcYkjaXVcô^c\gjWWZglî]bV\cZh^jb#*) &hi BV\cZh^jb 6hhdX^Vi^dc 6ccjVa BZZi^c\/ 8dkZgV\Z d[ i]Z&hiBV\cZh^jb6hhdX^Vi^dc6ccjVaBZZi^c\!]ZaY^c CZl Ndg` dc DXidWZg (")! &.))! ViiZcYZY Wn dkZg '*% ViiZcYZZh!lVhZmiZch^kZ;^\jgZ'.#**6ii]VibZZi^c\! Figure 27. Cast magnesium bomber wheels being ‘Wheelabrator’ 9g# LâaVgY 9dl \VkZ V heZZX] dc ¸BV\cZh^jb¶IdYVn cleaned at American Foundry.46 VcY Idbdggdl¹ ^c l]^X] ]Z higdc\an egdbdiZY i]Z gdaZd[bV\cZh^jb^ci]ZedhilVgZgV#=Z[Zaii]Vii]^h >c &.)(! dcZ d[ i]Z aZVY^c\ Vjidbdi^kZ VcY V^gXgV[i ldjaYgZfj^gZV\gdl^c\eg^kViZ^cYjhignjc]VbeZgZYWn YZh^\cZgh d[ 9Zigdî! c i]^h nZVg! i]Z Vajb^cjb ^c VjidbdWâZh VcY V^gXgV[i#), >c Xî^c\ dcZ bâîVgn cZZYh [dg bV\cZh^jb! ZheZX^Vaan ^c V^gXgV[i! eVgi^XjaVg ^cÄjZcXZ dc edhilVg Vjidbdi^kZ YZh^\c! ZmXZZYZY i]Z egdYjXi^dc XVeVXîn d[ i]Z ^cYjhign# ;dg ]Z Xdch^YZgZY i]Z Xdcig^Wji^dc bV\cZh^jb VcY Vahd LL>>V^gXgV[i!ZcdgbdjhfjVciî^Zhd[bV\cZh^jblZgZ Vajb^cjbXdjaYbV`ZidgZYjX^c\Zc\^cZlZ^\]i#=Z gZfj^gZY [dg a^fj^Y VcY V^g XddaZY Zc\^cZh! l]ZZah! dâ hiViZYi]Vi!¸I]ZVjidbdi^kZ^cYjhign!i]ZbdhiXdchX^djh iVc`h![gVbZhigjXijgZh!^chigjbZci]djh^c\h!\ngd[gVbZh! VcY i]Z idj\]Zhi XdbeZiîdg dc i]Z ^cYjhig^Va [gdci! VcY bVcn di]Zgh! d[iZc gZfj^g^c\ bVcn i]djhVcYh d[ h]djaYh]dli]ZlVn^ci]ZjhZd[cZlZgbZiVah_jhiVh idchd[bV\cZh^jbVaadnh^cZVX]eaVcZ#6aa"bV\cZh^jb [VhiVhi]^hXdbeZiî^dcbV`Zhi]Z^gjhZegVXi^XVa#¹ l^c\hlZgZiZhiZYhjXXZhh[jaan^chZgk^XZ#6gbnVcYcVkn 6h[dgV^gXgV[i!LVa`ZgXîZYi]Z^cÄjZcXZd[bV\cZh^jb lZgZi]Zc^ckZhi^\Vi^c\i]ZjhZd[bV\cZh^jb^cbdWâZ dcedhilVgYZh^\c!VhZmZbea^ÃZYWni]Z¸;an^c\L^c\¹ ZfjêbZci# GZfj^gZbZcih [dg bV\cZh^jb"XdciV^c^c\ ineZd[eaVcZ;^\jgZ'-#=Zcgn@V^hZgegdedhZYhjX]Vc Vajb^cjbVaadnh^ch]ZZiVcYZmigjh^dc[dgblZgZXgî^XVa V^gXgV[i!YZh^\cZY[dgheZZYVcYbVcZjkZgVWâîn!bVYZ VhlZaaYjg^c\i]Vii^bZ# aVg\Zandjid[bV\cZh^jb0îlVhaViZgWjâiWnCdgi]gde BVcn a^\]ilZ^\]i bV\cZh^jb Veea^XVi^dch lZgZ 6^gXgV[i8d#VcYÄdlcVhV_ZiegdeZaaZYegdidineZ# YZkZadeZYVcYWZ^c\Xdch^YZgZYVii]Zi^bZi]Viadd`ZY >c &.)(! ^c fj^X` hjXXZhh^dc V[iZg i]Z ^cVj\jgVa WZndcYLL>>!hjX]Vh/*)!*+ ^hhjZ! i]Z ?jan VcY HZeiZbWZg ^hhjZh d[ AB6 XdkZgZY EdhilVgV^gXgV[ihigjXijgZhVcYXdbedcZcih bV\cZh^jb hVcY XVhi^c\ [dg V^gXgV[i Veea^XVi^dch!)- H]êe^c\XdciV^cZgh bVX]^c^c\ X]VgVXiZg^hi^Xh d[ bV\cZh^jb!). kVg^Vi^dch ^c ;VcVcYegdeZaaZgWaVYZh ZaVhi^XbdYjajhbZVhjgZbZcihd[bV\cZh^jb!*%Xdggdh^dc 7^XnXaZ[gVbZh 11 Figure 29. Magnesium Association luncheon at the 1st Annual Meeting in New York on October 3-4, 1944.

BdidgXnXaZ[gVbZh bâa^dcedjcYhjhZYWn^cYjhign!&(bâa^dcedjcYhjhZY HXddiZgh [dgVaadn^c\Vajb^cjbVcYdi]ZgbZiVah!VcY&*bâa^dc EcZjbVi^Xidda]djh^c\h edjcYh^cbZai^c\VcYdi]ZgadhhZh#*, 7VWnXVgg^V\Zh BV\cZh^jb EdhilVg/*- >c heîZ d[ i]Z Z[[dgih eji [dgi] 8VcdZh id bV^ciV^c i]Z bV\cZh^jb bVg`Zi ^c eZVXZi^bZ! L]ZZaWVggdlh egd_ZXi^dch [dg edhilVg bV\cZh^jb Veea^XVi^dch lZgZ ;djcYgneViiZgch[dghVcYXVhi^c\[ZggdjhVcYcdc" dkZgandei^b^hi^XVcY!Wn&.)+!YZbVcYldgaYl^YZ[ZaaWVX` [ZggdjhbZiVah idegZ"lVgaZkZah!ldgaYegdYjXi^dcXVeVXîn[Zaaid&%!%%% IZmiâZbVX]^cZgnXdbedcZcih bi!VcYhjeeanVcYXdchjbei^dcY^YcdihiVgiidWjâYje 6gi^ÃX^Vaa^bWh[dgi]ZlVgldjcYZYkZiZgVch jciâ&.-%#6[iZgLL>>!i]ZJ#H#\dkZgcbZciegZeVgZYid 7gVXZh[dg^c[VciâZeVgVanh^hXVhZh Y^kZhiîhZa[d[bV\cZh^jbeaVcihVcY[VXâî^Zh!Vai]dj\] ;jgcîjgZ î Xdch^YZgZY bVcn [VXidgh id bV^ciV^c^c\ V ]ZVai]n =VgYlVgZîZbh bV\cZh^jb ^cYjhign V\V^chi [jijgZ ZbZg\ZcX^Zh# I]Z 8VbZgVVcYbdi^dce^XijgZZfjêbZciXdbedcZcih Y^hedhî^dc d[ aZVhZh VcY dei^dch dc bV\cZh^jb bZiVa IneZlgîZgh eaVcihVcY[VWg^XVi^dc[VXâî^ZhlVh[VXâîViZYi]gdj\]dji IgVâZgh &.)+Wni]ZJ#H#HjgeajhEgdeZgin6Yb^c^higVi^dc# 8dckZndgXdbedcZcih DcXZ eg^kViôZY! i]Z bV\cZh^jb ^cYjhign Xdci^cjZY I^gZbdaYh id bV`Z h^\c^ÃXVci ^begdkZbZcih ^c XdVi^c\h! ;^gZZmi^c\j^h]Zgh bZiValdg`^c\egdXZhhZh!XVhi^c\bZi]dYh!VcYVaadn^c\# AVYYZghVcYhXV[[daYh BVcn d[ i]Z edhilVg Veea^XVi^dch eaVccZY lZgZ 6jidbdWâZh!WjhZh!VcYigjX`h YZkZadeZY Vh egdidineZh dg XdbbZgX^VaôZY egdYjXih# AdVY^c\gVbeh 6\V^c bVcn edhilVg bV\cZh^jb YZkZadebZcih lZgZ ^c V^gXgV[i!^cXajY^c\V_ZiegdeZaaZYÄn^c\l^c\*.dg^\^cVaan >c dcZ Zhi^bViZ d[ edhi"LL>> Xdchjbei^dc! idiVa egdedhZYWn=Zcgn@V^hZg),VcYi]Z7"(+WdbWZg;^\jgZ VccjVaXdchjbei^dclVhhaViZYidWZ''-bâa^dcedjcYh! (%#+%I]Z7"(+WdbWZgjhZYVidiVad['%!%%%edjcYhd[ lî] &%% bâa^dc edjcYh jhZY ^c V^gXgV[i! Vcdi]Zg &%% bV\cZh^jb^cXVhi^c\h![dg\^c\h!VcYh]ZZi#=dlZkZg!Vi 12 Figure 29. Magnesium Association luncheon at the 1st Annual Meeting in New York on October 3-4, 1944. i]Z hVbZ i^bZ! \gdjcY kZ]^XaZh WZcZÃiZY Vh lZaa [gdb h^\c^ÃXVcihig^YZhYjg^c\i]^heZg^dY#G9VibV\cZh^jb i]Za^\]ilZ^\]i^c\i]VilVhbVYZedhh^WaZWnbV\cZh^jb XdbeVc^Zh egdk^YZY bVcn VchlZgh id fjZhi^dch VWdji ;^\jgZ(&# e]VhZZfjâ^Wg^V!Vaadn^c\Z[[ZXih!VcYi]ZgZaVi^dch]êd[ BV\cZh^jb ^c i]Z &.*%h/+' >c heîZ d[ V heVghZ edhilVg higjXijgZ VcY egdeZgi^Zh# CZl 6HIB bV\cZh^jb Vaadn bVg`Zi!h^\c^ÃXVcibV\cZh^jbYZkZadebZcihlZgZbVYZ cdbZcXaVijgZVcYiZbeZgYZh^\cVi^dchlZgZVYdeiZYWn ^c i]Z &.*%h! ^cXajY^c\ bVcn cZl XdVi^c\h id egdiZXi I]ZBV\cZh^jb6hhdX^Vi^dc# i]ZbV\cZh^jbVaadnh[gdbXdggdh^dcVcY^begdkZlZVg 6abdhi +) d[ bV\cZh^jb jhZY ^c i]Z J#H# Vi i]Z X]VgVXiZg^hi^Xh#6cdY^X!ZaZXigdaZhh"C^!VcY8g"eaVi^c\d[ WZ\^cc^c\d[i]Z&.*%hlVh^chigjXijgVaVeea^XVi^dch!]Va[ bV\cZh^jblZgZjhZY^c]^\]egdYjXi^dcVeea^XVi^dch# d[ l]^X] lZci ^cid V^gXgV[i VcY \gdjcY igVchedgiVi^dc# K^VWaZ XZgVb^X$edgXZaV^c XdVi^c\h [dg bV\cZh^jb EgdYjXi Veea^XVi^dch [dg bV\cZh^jb ZmeVcYZY ^c i]Z lZgZ YZkZadeZY# EgdXZhhZh [dg XaVYY^c\ d[ bV\cZh^jb XdbbZgX^Va hZXidg ^c i]Z &.*%h# HVbhdcîZ ^cigdYjXZY h]ZZiVcYeaViZVaadnhlî]di]ZgbV\cZh^jbVaadnhVcY V a^cZ d[ a^\]ilZ^\]i aj\\V\Z bVYZ lî] k^cna XdViZY Vajb^cjb lZgZ YZkZadeZY# Hd lZgZ cZl bV\cZh^jb bV\cZh^jb# BV\cZh^jb Y^Z XVhi^c\h lZgZ jhZY ^c edlYZgbZiVaajg\negdXZhhZh#KVg^djhlZaY^c\!WgVo^c\! Vjidbdi^kZ Veea^XVi^dch hjX] Vh hiZZg^c\ Xdajbc VY]Zh^kZWdcY^c\!VcYbZX]Vc^XVa[VhiZc^c\iZX]c^fjZh h]gdjYh! WgVX`Zih! ^chigjbZci XdkZgh! VcY di]Zg hZb^" [dg_d^c^c\bV\cZh^jblZgZeZg[ZXiZY#BV\cZh^jbjhV\Z higjXijgVa eVgih# I]Zn Vahd [djcY l^YZ Veea^XVi^dc ^c ^ci]ZgZYjXi^dcd[iîVc^jbVcYo^gXdc^jb\gZl#B\"G:! Wjh^cZhh bVX]^cZh! edgiVWaZ iddah! XVbZgVh! W^cdXjaVgh! B\"I]!VcYB\"I]"Og]^\]iZbeZgVijgZVaadnh[dgjhZVi VcYegd_ZXidgh# iZbeZgVijgZhd[)%%",%%d;lZgZbVYZVkVâVWaZ!]dlZkZg! 6 cZl hZb^"gVX^c\ XaVhh VjidbdWâZ lVh bVYZ ^c i]Z^gXdhia^bîZYi]Z^gVeea^XVi^dchidhjeZghdc^XV^gXgV[i 7gîV^cWn:hhZm6ZgdAiY#lî]V&('edjcYbV\cZh^jb VcYb^hhâZXdbedcZcih# dcZe^ZXZWdYnlZaYZY[gdbh]ZZi#BV\cZh^jbVahdbZi BV\cZh^jbY^ZXVhi^c\iZX]c^fjZhWZXVbZgZÃcZYVcY bVcnd[i]ZbâîVgncZZYhVii]Zi^bZ!Z#\#!a^\]ilZ^\]i l^YZanjhZYidbV`ZZc\^cZ"Yg^kZciddahX]V^chVlh!edhi bV\cZh^jb [gVbZ h]ZaiZgh [dg bâîVgn kZ]^XaZh! i]^c ]daZY^\\Zgh!ZiX##9dl8]Zb^XVa8d#YZkZadeZYi]Z]di bV\cZh^jbhigê[dgheZX^VabâîVgnWViiZgnVeea^XVi^dch! X]VbWZg Y^Z XVhi^c\ egdXZhh [dg bV\cZh^jb# 8VhiZgh! \j^YZY b^hhâZ Veea^XVi^dch! bdWâZ gVYVg ^chiVaaVi^dch! [dg\Zgh!ZmigjYZgh!VcY[VWg^XVidghd[bV\cZh^jbbVYZ VcY idda^c\ eaViZ [dg V^gXgV[i [VWg^XVi^dc# =dlZkZg! ^c 13 BV\cZh^jb ^c i]Z &.+%h/+) ;dg bV\cZh^jb! i]Z &.+%h lZgZi]ZYdaYgjbh!ZheZX^Vaan^ci]ZJ#H#7ni]Z&.+%h! bVcn bV\cZh^jb Veea^XVi^dch lZgZ YZkZadeZY VcY h]dlc id WZ egVXi^XVa ^c jhZ# ;dg ZmVbeaZ! Vi i]Z &,i] 6ccjVaBV\cZh^jb6hhdX^Vi^dcbZZi^c\^c&.+&!i]ZgZ lVhVcZm]^Wîd[¸&*%8dbbZgX^VaJhZhd[BV\cZh^jb#¹ HdbjX]kVg^ZinVcYfjVciînd[XdbbZgX^VaVeea^XVi^dch hjgeg^hZYbVcnd[i]ZViiZcYZZh#NZi!lî]J#H#eg^bVgn egdYjXi^dcV[ZZWaZ)&!%%%bi!i]ZnZVg&.+&lVhYjWWZY ¸i]Z nZVg d[ hiVcY^c\ hiâa¹ ZmZbea^[n^c\ Vcdi]Zg nZVg d[ Xdchda^YVi^dc d[ egZk^djhan YZkZadeZY Veea^XVi^dch# 8dchjbei^dcd[bV\cZh^jb^cCdgi]6bZg^XV^c&.+& lVhhiV\cVciWjicdihd^c:jgdeZYjZid'%!%%%"'*!%%% idch WZ^c\ jhZY ^c dcZ Veea^XVi^dc ^c c i]^h VZgdheVXZ bVg`Zi! XdbbZgX^Va V^ga^cZgh VkZgV\ZY (+% edjcYhd[bV\cZh^jb^cZVX]edlZgeaVci^chiVaaVi^dc! hVk^c\&-%edjcYheZgZc\^cZdg,'%edjcYh^cV^gXgV[i lZ^\]idkZgVaa# Figure 31. American Stores panel truck bodies of magnesium (supplied by Revere Copper and Brass Inc.) weighing 2100 pounds against 3600 pounds in steel.61

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Figure 33. Magnesium was speciÞed for doors and panels of the Minuteman missile shipping container in order to keep the shipment within highway load limits.65

>c]^hVYYgZhhVii]Z'(gY6ccjVaBV\cZh^jb6hhdX^Vi^dc bZZi^c\^c&.++!egZh^YZciGd\ZgL]ZZaZghV^Yi]Vii]Z bV\cZh^jb ^cYjhign ]VY [VâZY ^c i]Z eVhi &* nZVgh id iV`Z îh eaVXZ Vh V WVh^X ^cYjhig^Va XdbbdYîn bZiVa ^c i]ZJ#H#EZgXVeîVXdchjbei^dcd[bV\cZh^jb^c&.+* Vi+*!%%%bilVhWZadli]Vi^c&.*&0i]^hlVh&$&%i]d[ l]Vi lVh Zhi^bViZY V YZXVYZ ZVga^Zg# L]ZZaZg ed^ciZY djii]Vi[jijgZ\gdli]YZeZcYZYdchigjXijgVabVg`Zih dkZg X]Zb^XVa VcY bZiVaajg\^XVa bVg`Zih! VcY i]Vi i]Z Vjidbdi^kZbVg`ZilVhi]ZbdhiajXgVi^kZ#=ZcdiZY!¸>[ 6bZg^XVc VjidbdWâZ bVcj[VXijgZgh jhZY bV\cZh^jb ^c i]Z^g kZ]^XaZh ^c i]Z hVbZ gVi^d Vh ciZgcVi^dcVa BV\cZh^jb 6hhdX^Vi^dc >B6 'cYViHZWg^c\#Di]ZgbV\cZh^jbeVgihdci]Z.&&hZg^Zh lVh [dgbZY ^c &.,) [gdb i]Z BV\cZh^jb 6hhdX^Vi^dc! 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The six-cylinder die cast magnesium crankcase in production for the 1968 Porsche 911 series.66 J#H#7Zh^YZhi]ZgZXZhh^dcV[[ZXi^c\i]ZJ#H#VjidbdWâZ VcY WjâY^c\ VcY XdchigjXi^dc ^cYjhig^Zh Vi i]Vi i^bZ! 7n&.+,!^ci]ZJ#H#!bV\cZh^jbegdYjXi^dchiddYVi \dkZgcbZci gZhig^Xi^dch lZgZ ^bedhZY dc aZVYZY VWdji .,!%%% bi VcY Xdchjbei^dc Vi ..!%%% bi# I]Vi \Vhda^cZjhZ[dgl]^X]bV\cZh^jblVhjhZYVhVXViVanhi nZVg! i]Z \gdli] d[ i]Z Vajb^cjb bVg`Zi ^c \ZcZgVa [dgbedgiVcibV\cZh^jbVgi^XaZh ejWa^h]ZY^cAB6^ci]Z&.,%hgZedgiZYdccZlbV\cZh" ^jbegdYjXi^dc[VXâî^Zh!jhZd[bV\cZh^jb^cVaadn^c\ Vajb^cjb! heZX^Va bV\cZh^jb Veea^XVi^dch [dg C6H6! bV\cZh^jbXdbedhîZbViZg^Vah!cZl]^\]iZbeZgVijgZ bV\cZh^jbVaadnh!cZlbV\cZh^jb"XdciV^c^c\VYYî^dch [dg YZhjae]jgô^c\ hiZZa VcY cdYjaVgô^c\ XVhi ^gdc! bV\cZh^jb^co^gXdc^jbegdYjXi^dc!XdkZgV\Zd[Gjhh^Vc bV\cZh^jbG9!gZeZViZYbZci^dcd[¸ediZci^Va¹jhZh d[bV\cZh^jb^ci]ZVjidbdi^kZ^cYjhign!bZai]VcYa^c\ ^cY^ZXVhi^c\h]deh!cZlÄjm^c\bZi]dYh!]diX]VbWZg Y^ZXVhi^c\!hfjZZoZXVhi^c\!gZXnXa^c\d[bV\cZh^jb!cZl VcdYô^c\ egdXZhhZh [dg bV\cZh^jb! 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