0DJQHVLXP:KHUH+DYH:H%HHQ:KHUH$UH:H*RLQJ" $ 6WhigVXi [dgbVi^dc VWdji i]Z VYkVciV\Zdjh egdeZgi^Zh d[ bV\" cZh^jbVcY^ihVaadnh# ^cXZ^ihÃghiejWa^XVi^dc^cBVn&.)(!A^\]iBZiVa >c hjbbVg^o^c\ YZXVYZh d[ bV\cZh^jb egd\gZhh! 6\ZbV\Vo^cZ]VhWZZcXdaaVi^c\i]Zegd\gZhhVcY ^cXajY^c\ i]Z ¸jeh VcY Ydlch!¹ i]Z fjZhi^dch id WZ i]Z ZXdcdb^X jeh"VcY"Ydlch d[ bV\cZh^jb! i]Z VchlZgZY·l]ZgZ]VkZlZWZZc!l]ZgZVgZlZ\d^c\4· a^\]iZhid[i]ZXdbbdY^ina^\]ibZiVah#HiVgi^c\l^i] VgZeZg]VehWZhiVchlZgZYWnhiVgi^c\l^i]i]ZegZhZci! i]ZÃghi^hhjZd[H A^\]iBZiVa6\Z!^ih[djcYZg!Gdn;Zaadb?g# ^#Z#!l]ZgZVgZlZcdl4 lgdiZVWdjii]ZbV\cZh^jbegdYjXi^dcegdXZhhZhd[i]Z i^bZh bjX] i]Z hVbZ idYVn# I]^h Vgi^XaZ hjbbVg^oZh BV\cZh^jb/L]ZgZ6gZLZCdl4 i]Z egd\gZhh bVYZ ^c bV\cZh^jb iZX]cdad\n i]gdj\] i]Z YZXVYZh! l^i] Zbe]Vh^h dc i]Z jhZ d[ bV\cZh^jb# 9ZhXg^W^c\ i]Z egZhZci h^ijVi^dc ^c i]Z ldgaY d[ I]Z nZVg &.)( lVh V lViZgh]ZY nZVg [dg bV\cZh^jb bV\cZh^jb! ^i ^h Vei id eVgVe]gVhZ 8]VgaZh 9^X`Zch ^c egdYjXi^dc!l^i]ldgaYl^YZegdYjXi^dceZV`^c\i]VinZVg XVeijg^c\i]ZZhhZcXZd[VcZck^gdcbZci^ci]Zb^Yhid[ YjZidi]ZlVgZ[[dgiVcYi]Zc[Vaa^c\egZX^e^idjhanVii]Z ijgbd^aVcYX]Vc\Z/ ZcYd[LL>>WnV[VXidgd[*%i^bZh#>iidd`YZXVYZh[dg I]ZhZVgZi]ZWZhid[i^bZh0i]ZhZVgZi]Zldghid[i^bZh# i]Z bVg`Zi id gZXdkZg id l]ZgZ ^i ^h idYVn·hdbZ [djg I]Zedh^i^kZh^YZd[i]ZegZhZcibV\cZh^jbhXZcVg^d i^bZhi]ZldgaYl^YZegdYjXi^dcaZkZaYjg^c\^iheZV`^c ]VhbVcn[VXZih!bVcnd[l]^X]VgZbVYZVeeVgZciVii]Z LL>>·l^i]XgZY^iYjZ^caVg\ZeVgiidi]ZgZbVg`VWaZ +*i]6ccjVaLdgaYBV\cZh^jb8dc[ZgZcXZ0i]ZcZ\Vi^kZ egdeZgi^Zh d[ i]^h a^\]i bZiVa VcY id i]Z djihiVcY^c\ h^YZd[i]ZegZhZcibV\cZh^jbhXZcVg^d!Vh^ih]djaY!^h ldg`d[bV\cZh^jbiZX]cdad\^hih^cXgZVi^c\VaadnhVcY kd^XZY]ZgZVhlZaa# egdXZhhZhi]Vid[[ZgVYkVciV\ZhVcYkVajZ^cXdbbZgX^Va >ci]ZXdciZmid[i]ZegZhZci\adWVaZck^gdcbZci[dg Veea^XVi^dch#I]ZhZigZcYh^cbV\cZh^jbiZX]cdad\nVh bV\cZh^jb! dei^b^hih bVn WZa^ZkZ ¸i]Z XgjX^WaZ ^h ]Va[ lZaaVhi]ZjhZhd[bV\cZh^jb]VkZWZZcYdXjbZciZY^c [jaa¹VcYi]ZhZVgZi]ZWZhid[i^bZh#>cYZZY!i]Z[daadl^c\ A^\]iBZiVa6\Z#JedcXjghdgnZmVb^cVi^dcd[i]ZbVcn edh^i^kZ VheZXih [dg i]Z bV\cZh^jb ^cYjhign bVn WZ YZXVYZhd[bV\cZh^jbjhV\Z!lZViÃghihZchZVXVhZd[ X^iZY/ ¸]^hidgn gZeZVi^c\ ^ihZa[¹ Wji! Y^\\^c\ YZZeZg ^cid i]Z JDcVldgaYl^YZWVh^h!bV\cZh^jbegdYjXi^dchZiV bV\cZh^jb VgX]^kZh! lZ hZZ ]dl Xg^i^XVa i]Z egd\gZhh gZXdgY^c'%%, bVYZWnbV\cZh^jbiZX]cdad\^hih]VhWZZc^cZmeVcY^c\ J CZl bV\cZh^jb egdYjXi^dc egdXZhhZh ]VkZ WZZc ^ihjhZ^cVl^YZkVg^Zind[bVg`Zih# YZkZadeZYi]ViXVch^\c^ÃXVcian^begdkZZ[ÃX^ZcXnVcY gZYjXZXVe^iVaXdhih >cigdYjXi^dc JI]Z[dXjhd[kZ]^XaZbVcj[VXijgZghdca^\]ilZ^\]i^c\ Vj\jgh lZaa [dg ^cXgZVh^c\ jhZ d[ bV\cZh^jb Vaadnh ^c I]ZÃghi^hhjZd[A^\]iBZiVa6\ZlVhYZY^XViZYidi]Z higjXijgVaVcYedlZgigV^cVeea^XVi^dch!i]ZgZWnZmeVcY^c\ cZlV\Zd[bZiVah·i]ZA^\]iBZiVa6\Z·i]ViVh^ihÃghi i]ZediZci^VabVg`Zi[dgbV\cZh^jbh^\c^ÃXVcian ejWa^h]ZgGdn;Zaadb?g#&.&("&..(YjancdiZYi]Zc^c JG9egd\gVbhi]Vi]VkZWZZc^ceaVXZh^cXZi]Z&..%h ]^hZY^idg^Va/ VgZWZVg^c\[gj^i^cbZZi^c\i]ZX]VaaZc\ZhbV\cZh^jb ¸Djid[i]ZXgjX^WaZd[lVghi]gdj\]dji]^hidgn]VkZ [VXZh [gdb XdbeZi^c\ bViZg^Vah ^c a^\]ilZ^\]i^c\ WZZcWdgci]Z\gZViV\Zhd[bVc¶i]ZHidcZ6\Z!i]Z kZ]^XaZh 7gdcoZ6\Z!i]Z>gdc6\Z!i]ZHiZZa6\Z°=^hidgn^hV\V^c JCZlbV\cZh^jbVaadnh]VkZWZZcgZXZcianYZkZadeZY gZeZVi^c\ ^ihZa[#°A^\]i BZiVa bV\cZh^jb! Vajb^cjb! i]Vi ]VkZ i]Z egdeZgi^Zh VcY gZfj^gZbZcih id Y^heaVXZ VcYi]Z^gVaadnh^hi]ZX]^aYd[i]ZegZhZcilVg#°>il^aaWZ XdbeZi^i^kZa^\]ilZ^\]ibViZg^Vah^cedlZgigV^cVeea^XVi^dch VcZgVd[EZVXZl]ZgZ^cA^\]iBZiVal^aaWZi]ZYdb^cVci J I]Z a^\]ilZ^\]i Xdbedh^iZ Vajb^cjb"bV\cZh^jb bZiVa ^c i]Z ÃZaY d[ Veea^ZY bVcj[VXijgZ#°6 igjan Zc\^cZ WadX` YZkZadeZY Wn 7BL lVh VkV^aVWaZ dc Vaa b^gVXaZbZiVai]Vil^aaWZXdbZi]ZhigjXijgVabViZg^Vad[ i]Z^gVjidbdW^aZh^c'%%,VcYgZXZ^kZY]^\]gVi^c\h ^cYjhign [dg VjidbdW^aZh! igjX`h! igV^ch! igVXidgh! h]^eh! J6YkVcXZh]VkZWZZcbVYZ^cbV\cZh^jbegdXZhh^c\ Zc\^cZh! iddah! Wjh^cZhh bVX]^cZh! XgVcZh! Wg^Y\Zh! VcY id XgZViZ aVg\Z h^oZ! i]^c lVaa! ]^\] ^ciZ\g^in higjXijgVa h`nhXgVeZgh! VcY l^aa bVg` i]Z Vgg^kVa d[ i]Z A><=I XVhi^c\h B:I6A6<:#¹ J BV\cZh^jb Vaadn XVhi^c\ VcY hZb^hda^Y [dgb^c\ egdXZhhZhVcYiZX]cdad\^ZhVgZViVcVYkVcXZYhiViZd[ Hjeedgi^c\]^hk^Zld[i]Z[jijgZaV^YYdlc++nZVgh YZkZadebZciVcYegdYjXi^dcZ[ÃX^ZcXn V\d! Gdn ldjaY ]VkZ WZZc eaZVhZY id hZZ i]Z egd\gZhh J8dci^cjdjhanXVhibV\cZh^jbVaadnh]ZZiVcYhig^e bVYZ^cVeea^XVi^dchd[bV\cZh^jbVcY^ihVaadnhidYVn! VgZ cdl WZ^c\ egdYjXZY XdbbZgX^Vaan Wn il^c gdaa VaWZ^i^c^cYjhig^ZhYZkZadeZYh^cXZi]Zc·XVhZh[dgXZaa XVhi^c\VcYgdaa^c\d[[Zg^c\VYkVciV\ZhdkZgY^gZXiX]^aa e]dcZhVcYaVeideXdbejiZgh!XdbedcZcih[dghViZaa^iZh 98XVhi^c\diVcYgdaa^c\VcYdeZc^c\i]ZYddgl^YZg VcY heVXZ egdWZh! VYkVcXZY kZ]^XaZ edlZgigV^ch! VcY [dgbV\cZh^jbh]ZZiVeea^XVi^dch bVcn di]Zg bV\cZh^jb Veea^XVi^dch YZhXg^WZY Vi i]Z JDei^dchVgZcdlVkV^aVWaZ[dgbV\cZh^jbegdYjXZgh +*i] 6ccjVa LdgaY BV\cZh^jb 8dc[ZgZcXZ d[ i]Z idVYYgZhh\adWValVgb^c\XdcXZgchVcYgZYjXZZcZg\n >ciZgcVi^dcVa BV\cZl^jb 6hhdX^Vi^dc >B6! BVn &-i] Xdchjbei^dcVcY8D'Zb^hh^dch "'%i]!'%%-^cLVghVl!EdaVcY#6aad[i]ZVYkVcXZbZcih J8daaVWdgVi^dcVcYcZildg`^c\Vbdc\eZZghldgaY" bVYZ^ci]Zl^YZgjhV\Zd[bV\cZh^jbVcY^ihVaadnh]VkZ l^YZ ^c bV\cZh^jb G9 VcY iZX]cdad\n igVch[Zg WZcZÃiZYdkZgi]ZnZVgh[gdbi]ZVYkVcXZbZcihbVYZ^c ]Vh cZkZg WZZc WZiiZg! ZbedlZgZY Wn Xdjcign VcY YZkZadebZcid[WZiiZgbV\cZh^jbVaadnh!^begdkZbZcih ^ciZgcVi^dcVaWVhZY[dgjbhhjX]Vh>B6Xdc[ZgZcXZh!d[ bVYZ^chigjXijgVaYZh^\chl^i]bV\cZh^jbVaadnh!XVhi^c\ XdjghZ!VcYWnldgaYl^YZlZWgZhdjgXZh VcYhZb^hda^YegdXZhh^ccdkVi^dch!ldgaYl^YZbV\cZh^jb JDei^b^hihndj`cdll]dndjVgZXVcVYYidi]Z G9 cZildg`^c\! VcY l^YZhegZVY Y^hhZb^cVi^dc d[ ^c" a^hi 1 I]ZgZVgZhdbZcZ\Vi^kZVheZXihVhlZaa^ci]ZegZhZci \adWVaZck^gdcbZci[dgbV\cZh^jb!VcYeZhh^b^hihbVn WZa^ZkZi]Z¸XgjX^WaZ^h]Va[Zbein¹VcYi]Vii]ZhZVgZi]Z ldghid[i^bZh/ L>che^iZd[gZXdgYldgaYl^YZegdYjXi^dc!i]ZXdhid[ bV\cZh^jbhe^gVahjelVgY L J#H# Vci^Yjbe^c\ aVlh ]VkZ XjgiV^aZY ^bedgih d[ bV\cZh^jb [gdb 8]^cV! i]Z ldgaY»h aVg\Zhi eg^bVgn bV\cZh^jbegdYjXZg L Cdgi] 6bZg^XVc bV\cZh^jb Y^Z XVhiZgh VgZ higj\" \a^c\YjZidi]Z^bedhZYVci^Yjbe^c\aVlh^ci]ZJ#H# VcY id X]Vc\Zh VcY egdWaZbh ^c i]Z J#H# Vjidbdi^kZ ^cYjhign!l]^X]]VhigVY^i^dcVaanWZZci]ZaVg\ZhijhZgd[ bV\cZh^jbY^ZXVhi^c\h L;dgi]ZÃghii^bZh^cXZ&.)&!i]ZgZ^hcdbV\cZh^jb egdYjXi^dc^c8VcVYV!VcYbV\cZh^jbegdYjXi^dc]Vh XZVhZYgZXZcian^cJ`gV^cZVcYHZgW^VVhlZaa Figure 1. Robert E. “Bob” Brown receiving a lifetime achievement L I]Z egZhZci ]^\] Xdhi VcY adl VkV^aVW^a^in d[ award from the IMA at their 2007 annual meeting in Vancouver, B.C., bV\cZh^jb VcY ^ih 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]ZXdbeZi^i^kZegZhhjgZ[gdbdi]ZgbZiVah!eaVhi^Xh!Unusual Year for WorldegdYjXi^dc#¹=^hhjbbVgnX]Vgid[ldgaYl^YZbV\cZh^jb Magnesium in 2007 Xdbedh^iZh!VcYZkZclddY]VhcZkZgWZZc\gZViZg egdYjXi^dc^c'%%,^hh]dlc^cIVWaZ>!l]ZgZ^i^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[Ydadb^iZ XdcXZgch By Robert E. Brown, Contributingl^i][Zggdh^a^XdcE^Y\ZdcegdXZhh# Editor L Bdhi eg^bVgn bV\cZh^jb ^h egdYjXZY ^c 8]^cV ji^a^o^c\Vi]ZgbVaegdXZhhE^Y\Zdci]Vi^hcdl[VXZYIntroduction l^i] 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'%%,VhVigVYZYXdbbdY^inbZiVaYjZidi]Zstartling news (for the magnesium industry).” That hbVaah^oZd[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:jgdeZVc8dbbjc^inegd\gVb!bV\cZh^jbmedia except when a large fi re at a plant makes the nationall^aa 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\gVbl^aa[VXZbdgZhXgji^cn has forced major users to pay attention. Although magnesiumL 8dbeVgZY production l^i] XdbeZi^i^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\l^i]bV\cZh^jbVcY^ihVaadnhVeeZVghidWZ 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 lastVkV^aVW^a^ind[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 An 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]ZKL 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 in- dustries 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 ap- plication of magnesium and its alloys in automobiles has achieved remarkable progress, and magnesium applica- tions in automobiles and motorcycles have expanded steadily. The Chinese government has supported the applica- tion 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 commer- cialization 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 spe- cial 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 ji^a^oZh 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[dg^ihI^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\ZgVjidbdW^aZ;^\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 à nishing is covered. I]Z ¸IZVb 6jhigVa^V¹ Z[[dgi ^h X]VgVXiZg^oZY 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).L^i] 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^kZgh^i^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 à 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!¸ 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^dcW^aaZihl^i]ZmXZaaZci The Z06 aluminum spaceframe design (Figure 3) was hjg[VXZfjVa^in 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 H^ijVi^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 =dg^odch 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]^ebZcih [dg '%%, lZgZ Zhi^bViZY Vi '-!%%% bi! V YZXgZVhZ d[ s&%!%%% bi dkZg '%%+#&% 6k^hbV jhZh bV\cZh^jb bZiVa idgZVXil^i]i^iVc^jbiZigVX]adg^YZidegdYjXZi^iVc^jb bZiVa#>c?jan'%%,!7dZ^c\hZijeV_d^cikZcijgZJgVa 7dZ^c\BVcj[VXijg^c\l^i]i]ZldgaY»haVg\Zhii^iVc^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 i^iVc^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=dg^odchbZZi^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 lZgZegZhZciZYYZiV^a^c\!Vbdc\di]Zgh!egdYjXi^dcYViV cylindereVgih^cXdgedgViZY^cid^ihXdckZgi^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_ZXihl^i]^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,competitivel^i] 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 VkV^aVWaZthe Z06 from aluminum dc the i]Z die JH86G spaceframe casting lZWh^iZ/ 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 l^i]^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\g^in 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#8djcX^a[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]^eJH6BE!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]ZXg^i^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]^e [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-pres- sure 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 ele- ments. 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 magne- sium 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'%%,! BV\cZh^jbNZhiZgYVn&..*¶'%%) 6 BV\cZh^jb >ciZch^kZ KZ]^XaZ/ :cigZegZcZjgh]^e ]Vh WZZc VXi^kZ ^c bV\cZh^jb Vjidbdi^kZ Veea^XVi^dch! Vh Zk^YZcXZY Wn :VgaZ 8VcVkVc ;^\jgZ &-! l]d ]Vh WZZc VcY hi^aa ^h ^ciZci dc Wj^aY^c\ i]Z @V^hZg 9Vgg^c Vaa"bV\cZh^jb XVg VcY di]Zg Vaa"bV\cZh^jb kZ]^XaZh#'& 6ajb^cjb ^ciZch^kZ kZ]^XaZh 6>Kh ]VkZ YdcZ bjX] Figure 19. AM60B magnesium alloy wheel manufactured by Mg 12 id egdbdiZ a^\]ilZ^\]i Vajb^cjb ^c Vjidbdi^kZ RevolutionLtd.ofSouthAfricautilizingtheRafßeprocessandawarded the 2004 Annual Award of Excellence at the 2004 IMA meeting in New Orleans.22 >c V bV_dg Veea^XVi^dc d[ bV\cZh^jb ^c Vjidbdi^kZ [gdci ZcY higjXijgZh! 9V^baZg8]gnhaZg YZh^\cZY V [jaan ^ciZ\gViZY [gdci"d["YVh] ;D9 [dg i]Z^g '%%( K^eZg ;^\jgZ '%#'( I]Z ;D9 higjXijgZ! bVYZ Wn BZg^Y^Vc IZX]cdad\^Zh! lVh V dcZ e^ZXZ bV\cZh^jb Vaadn Y^Z XVhi^c\ VhhZbWaZY l^i] i]gZZ hiVbe^c\ hjWVhhZbWa^Zh i]Vi gZeaVXZY V bjai^e^ZXZ hiZZa VhhZbWan bVYZ d[ *& hiVbe^c\h#I]ZhiZZahigjXijgZlZ^\]ZY++edjcYhV\V^chi '&edjcYh[dgi]ZbV\cZh^jbhigjXijgZ# Hig^e8Vhi^c\d[BV\cZh^jbH]ZZiGZXdch^YZgZY/=^hidg^XVa Veea^XVi^dch d[ bV\cZh^jb Vaadn h]ZZi egdYjXZY Wn XdckZci^dcVagdaa^c\d[^c\diVcYi]Z\V^c^c\ViiZci^dc Figure 18. Earle Canavan holding a magnesium wheel preform Figure 20. The DaimlerChrysler 2003 Viper used a fully integrated above samples of other automotive magnesium parts made by the magnesium front dash structure made of a one-piece magnesium die Magnesium Automotive Group. casting.23 7 idil^cgdaaXVhi^c\VcYgdaa^c\d[bV\cZh^jbVaadnh]ZZi i]Z egdb^hZ d[ Vjidbdi^kZ bV\cZh^jb! ZmZbea^ÃZY Wn lZgZgZk^ZlZYWn7dW7gdlc^c;ZWgjVgn'%%'#')6bdc\ i]ZhjXXZhh[jaY^ZXVhibV\cZh^jb^chigjbZcieVcZa>E i]ZZVgan]^hidg^XVaVeea^XVi^dchd[cdiZ^cV^gXgV[ilVhi]Z XgdhhXVgWZVbh^cjhZWnVjidbV`Zgh;^\jgZ'&#I]ZhZ *%%`\&&%%aWhd[bV\cZh^jbh]ZZijhZY^ci]Z;dX`Z bV\cZh^jb>EhlZgZcdiXdch^YZgZYeVgid[i]Z[gdciZcY Lja[8dcYdg'%%X^k^a^VcV^gXgV[iWj^ai^c Figure 22. Potential magnesium components in an automobile and characteristics needed in these parts as of 1997 (courtesy Volkswagen Figure 24. Automotive magnesium castings on display at IMA-53 in AG). 37 Ube City, Japan.41 9 I]^mdbVi!>cX#!6cc6gWdg!B>#I]^mdbVi!>cX#!l]^X]]Vh bV^ciV^cZY^ih]ZVYfjVgiZgh^c6cc6gWdgVaai]ZhZnZVgh! ]Vhd[iZc^ck^iZYViiZcYZZhVi>B6»h6ccjVaBV\cZh^jb ^c6jidbdi^kZHZb^cVgVhlVhi]ZXVhZi]^hnZVgVii]^h &.i]>B6ZkZciidhZZVYZbdchigVi^dcd[i]ZegdXZhh#6i i]Zi^bZ!=EB8dgedgVi^dcWj^aii]ZÃghi¸I]^mdbdaYZg¹ ;^\jgZ '+ [dg i]^mdbdaY^c\ bV\cZh^jb VcY ]VY ^i ^chiVaaZY Vi i]Z A^cYWZg\ 8dgedgVi^dc eaVci ^c GVX^cZ! L># Figure 25. Design Award winner at IMA-53 for the six-piece Porsche Cabrio roof system die cast in AM50 alloy and the Application Award Figure 26. The 400-ton “Thixomolder” built by HPM Corporation.43 winner at IMA-53 for the cross beam/dashboard support die cast in AM60B alloy.41 BV\cZh^jbNZhiZgYVn&.)("&..) 6bZg^XVc Vjidbdi^kZ bVg`Zi lVh ZheZX^Vaan ^ck^i^c\ Vh lVhVeeVgZciVii]Z*'cY>B66ccjVaLdgaY8dc[ZgZcXZ >c gZk^Zl^c\ eVhi bV\cZh^jb Veea^XVi^dch WZndcY ]ZaY ^c HVc ;gVcX^hXd! 86 ^c &..*#)' 9ZbVcY [dg ildYZXVYZh!ZheZX^Vaan^chjX]VX]Vc\^c\Zck^gdcbZci bV\cZh^jb Vh Y^Z XVhi^c\h Vi i]Z ¸7^\ I]gZZ¹ Cdgi] ^c l]^X] i]Z \adWVa bV\cZh^jb ^cYjhign ÃcYh ^ihZa[ 6bZg^XVcVjidbdi^kZXdbeVc^ZhlVhegd_ZXiZYid\gdl egZhZcian!^i^heZg]VehegjYZciidbV`Z^ih]dgi#6XijVaan! Vi VWdji '% i]gdj\] &..- IVWaZ>K# :migVedaVi^dch bVcn d[ i]Z Vgi^XaZh gZk^ZlZY VcY gZ[ZgZcXZY ]ZgZ d[i]^hiVWaZbVYZ^igZVhdcVWaZidegZY^Xii]Vii]ZCdgi] XdciV^c bjX] ]^hidg^XVa eZgheZXi^kZ ZmiZcY^c\ [Vg ^cid 6bZg^XVc VjidbdW^aZ ^cYjhign ldjaY WZ jh^c\ +%!%%% i]ZeVhi#DkZgVaa!h^cXZ^ihÃghi^hhjZ!AB6]VhejWa^h]ZY bZig^Xidchd[bV\cZh^jbY^ZXVhi^c\h^ci]Zegd_ZXiZY ]jcYgZYh d[ Vgi^XaZh dc i]Z ZmigVXi^kZ bZiVaajg\n! &'b^aa^dckZ]^XaZhidWZWj^ai^c'%%%# Vaadn^c\! egdXZhh^c\! VcY Veea^XVi^dch d[ bV\cZh^jb# I]jh!VhlZgZk^Zli]ZZm^hi^c\VcYegdedhZYbV\cZh^jb Veea^XVi^dch [dg i]Z eZg^dY &.)("&..)! [dg i]Z hV`Z d[ WgZk^in!dcani]Z]^\]ed^cihVgZXdch^YZgZY]ZgZ#6cY! jca^`Z i]Z egZk^djh hZXi^dc BV\cZh^jb IdYVn '%%*" '%%- [ZVijg^c\ XdciZbedgVgn bV\cZh^jb Veea^XVi^dch VcYYZkZadebZcihadd`^c\WVX`^ci^bZ!^i^h^chigjXi^kZ VcY Zca^\]iZc^c\ id hiVgi Vi i]Z WZ\^cc^c\ BVn &.)( ^hhjZd[AB6VcYadd`[dglVgY[gdbi]Vii^bZidWZiiZg jcYZghiVcYi]ZZkdaji^dcd[bV\cZh^jb^cidi]ZbZiVa lZ]VkZidYVn# BV\cZh^jb[gdbi]ZEZgheZXi^kZd[&.)("&.))/BV\cZh^jb idd` V egdb^cZci edh^i^dc Yjg^c\ LL>> Vh V higViZ\^X gZhdjgXZ! l^i] V egdYjXi^dc XVeVX^in ^c &.)( WZ^c\ +% Table IV. Projections made in 1995 at IMA-52 for use of magnesium i^bZh\gZViZgi]Vc^c&.(.!^#Z#!eZV`egdYjXi^dcYjg^c\ die castings in vehicles produced in North America through 1998.42 LL>> lVh Veegdm^bViZan '('!%%% bi! bdhian [gdb i]Z &* eaVcih Wj^ai ^c i]Z J#H# 7n XdbeVg^hdc! egdYjXi^dc C^cZiZZc c^cZin"ÃkZ lVh Vahd i]Z i^bZ l]Zc i]Z XVeVX^ind[Vajb^cjb^c&.)(lVhÃkZi^bZh\gZViZgi]Vc EC BdidgXnXaZ[gVbZh b^aa^dcedjcYhjhZYWn^cYjhign!&(b^aa^dcedjcYhjhZY HXddiZgh [dgVaadn^c\Vajb^cjbVcYdi]ZgbZiVah!VcY&*b^aa^dc EcZjbVi^Xidda]djh^c\h edjcYh^cbZai^c\VcYdi]ZgadhhZh#*, 7VWnXVgg^V\Zh BV\cZh^jb EdhilVg/*- >c he^iZ 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\[ZggdjhVcYcdc" dkZgandei^b^hi^XVcY!Wn&.)+!YZbVcYldgaYl^YZ[ZaaWVX` [ZggdjhbZiVah idegZ"lVgaZkZah!ldgaYegdYjXi^dcXVeVX^in[Zaaid&%!%%% IZmi^aZbVX]^cZgnXdbedcZcih bi!VcYhjeeanVcYXdchjbei^dcY^YcdihiVgiidWj^aYje 6gi^ÃX^Vaa^bWh[dgi]ZlVgldjcYZYkZiZgVch jci^a&.-%#6[iZgLL>>!i]ZJ#H#\dkZgcbZciegZeVgZYid 7gVXZh[dg^c[Vci^aZeVgVanh^hXVhZh Y^kZhi^ihZa[d[bV\cZh^jbeaVcihVcY[VX^a^i^Zh!Vai]dj\] ;jgc^ijgZ ^i Xdch^YZgZY bVcn [VXidgh id bV^ciV^c^c\ V ]ZVai]n =VgYlVgZ^iZbh bV\cZh^jb ^cYjhign V\V^chi [jijgZ ZbZg\ZcX^Zh# I]Z 8VbZgVVcYbdi^dce^XijgZZfj^ebZciXdbedcZcih Y^hedh^i^dc d[ aZVhZh VcY dei^dch dc bV\cZh^jb bZiVa IneZlg^iZgh eaVcihVcY[VWg^XVi^dc[VX^a^i^ZhlVh[VX^a^iViZYi]gdj\]dji IgV^aZgh &.)+Wni]ZJ#H#HjgeajhEgdeZgin6Yb^c^higVi^dc# 8dckZndgXdbedcZcih DcXZ eg^kVi^oZY! 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 6jidbdW^aZh!WjhZh!VcYigjX`h YZkZadeZY Vh egdidineZh dg XdbbZgX^Va^oZY 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''-b^aa^dcedjcYh! (%#+%I]Z7"(+WdbWZgjhZYVidiVad['%!%%%edjcYhd[ l^i] &%% b^aa^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]VhZZfj^a^Wg^V!Vaadn^c\Z[[ZXih!VcYi]ZgZaVi^dch]^ed[ BV\cZh^jb ^c i]Z &.*%h/+' >c he^iZ 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# HVbhdc^iZ ^cigdYjXZY h]ZZiVcYeaViZVaadnhl^i]di]ZgbV\cZh^jbVaadnhVcY V a^cZ d[ a^\]ilZ^\]i aj\\V\Z bVYZ l^i] 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[i^iVc^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;lZgZbVYZVkV^aVWaZ!]dlZkZg! 6 cZl hZb^"gVX^c\ XaVhh VjidbdW^aZ lVh bVYZ ^c i]Z^gXdhia^b^iZYi]Z^gVeea^XVi^dchidhjeZghdc^XV^gXgV[i 7g^iV^cWn:hhZm6ZgdAiY#l^i]V&('edjcYbV\cZh^jb VcYb^hh^aZXdbedcZcih# dcZe^ZXZWdYnlZaYZY[gdbh]ZZi#BV\cZh^jbVahdbZi BV\cZh^jbY^ZXVhi^c\iZX]c^fjZhWZXVbZgZÃcZYVcY bVcnd[i]Zb^a^iVgncZZYhVii]Zi^bZ!Z#\#!a^\]ilZ^\]i l^YZanjhZYidbV`ZZc\^cZ"Yg^kZciddahX]V^chVlh!edhi bV\cZh^jb [gVbZ h]ZaiZgh [dg b^a^iVgn kZ]^XaZh! i]^c ]daZY^\\Zgh!ZiX##9dl8]Zb^XVa8d#YZkZadeZYi]Z]di bV\cZh^jbhig^e[dgheZX^Vab^a^iVgnWViiZgnVeea^XVi^dch! X]VbWZg Y^Z XVhi^c\ egdXZhh [dg bV\cZh^jb# 8VhiZgh! \j^YZY b^hh^aZ Veea^XVi^dch! bdW^aZ 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]^W^id[¸&*%8dbbZgX^VaJhZhd[BV\cZh^jb#¹ HdbjX]kVg^ZinVcYfjVci^ind[XdbbZgX^VaVeea^XVi^dch hjgeg^hZYbVcnd[i]ZViiZcYZZh#NZi!l^i]J#H#eg^bVgn egdYjXi^dcV[ZZWaZ)&!%%%bi!i]ZnZVg&.+&lVhYjWWZY ¸i]Z nZVg d[ hiVcY^c\ hi^aa¹ 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 &.**!jhZd[eg^bVgnbV\cZh^jbdcanVbdjciZYidVWdji **!%%%bi# Id ]^\]a^\]i i]Z gdWjhicZhh d[ bV\cZh^jb ^c ]^\]an X]VaaZc\^c\Veea^XVi^dchYjg^c\i]Z&.*%h!Xdch^YZgi]Z bV\cZh^jb ¸BZX]Vc^XVa BjaZ¹ ;^\jgZ (' YZkZadeZY Vii]Z9Zigd^i6ghZcVa[dgjhZWni]Z6gbnVcYBVg^cZ 8dgeh VcY d[ÃX^Vaan `cdlc Vh 8Vgg^Zg! A^\]i LZVedch! >c[Vcign! "idc! )m)! MB',)#+( I]Z ¸BjaZ¹ hZgkZY i]Z b^a^iVgncZZYh[dga^\]iZg!bdgZXdbeVXiZfj^ebZcii]Vi XdjaYWZV^gWdgcZVcYbdW^aZ# 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 [V^aZY ^c i]Z eVhi &* nZVgh id iV`Z ^ih eaVXZ Vh V WVh^X ^cYjhig^Va XdbbdY^in bZiVa ^c i]ZJ#H#EZgXVe^iVXdchjbei^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 VjidbdW^aZ bVcj[VXijgZgh jhZY bV\cZh^jb ^c i]Z^g kZ]^XaZh ^c i]Z hVbZ gVi^d Vh 18
<<