Under the leadership of Academician Fusheng Pan, the National Engineering Research Center for Magnesium Alloys (CCMg) and the National Key Laboratory of Advanced Casting Technologies of Chongqing University, Chongqing Millison Technologies Inc., and Chongqing Boao Magnesium Aluminium Manufacturing Company Ltd. jointly announced the successful trial manufacturing of the world's largest Mg-alloy integrated die-cast automotive components. Two ultra-large-scale components, namely a body part and an upper cover for battery enclosures, were cast using Meilixin's 8800T giant high-pressure die-casting (HPDC) machine. The projected area of both components surpasses 2.2m2, establishing them as the largest Mg-alloy automotive die-casting components presently obtainable. With a weight reduction of 32% compared to aluminum alloy castings, these Mg-alloy castings exhibit considerable potential for lightweight applications.
During this trial, Professor Bin Jiang's team from Prof. Pan’s group in CCMg developed cutting-edge technologies for high-fluidity Mg-alloys, treatment of large-volume Mg-alloy melts, optimization of die-casting structural design, prediction and control of casting defects, etc. These advancements greatly contributed to the successful casting of the ultra-large-scale Mg-alloy components. These technologies have established a solid foundation for the production and widespread application of ultra-large-scale magnesium alloy components in the automotive industry.
In recent years, numerous countries have introduced policies aimed at reducing greenhouse gas emissions, which has resulted in a widespread requirement for lightweighting in both traditional and electric vehicles. Magnesium alloys, being the lightest structural materials on Earth with a density only two-thirds that of aluminum alloys and one-fourth that of steel, are considered among the most promising lightweight metal materials.
In response to this demand, CCMg has actively engaged in exploration, innovation, and the development of technologies related to high-performance magnesium alloys and magnesium-based energy storage materials. These advancements have made significant contributions to the lightweight application of magnesium alloys in sectors such as electric vehicles, rail transportation, aerospace, and more.
The successful trial manufacturing of these ultra-large-scale magnesium alloy automotive components will further promote the widespread use of magnesium alloys in the automotive industry, which holds significant importance in addressing energy efficiency challenges globally.
International Mg Society