Advantages of magnesium are something necessary for the modern industry and metallurgy and they become from special magnesium characteristics. For example the automotive industry has crossed the doorstep from using magnesium in a protected environment, predominantly interior applications to an unprotected environment. Today you can see growing popularity of magnesium die casting, particularly in the automotive field. Many of interior magnesium components include instrument panel, seat frames, steering wheel and others. The most popular world production involves roof panels, hood, rear deck lid, wheels, oil pan, starter/alternator and so on. One really needed magnesium area is automotive industry and technologies.
Fuel saving advantages of magnesium used in vehicles gives it a large popularity. The data indicate that the overall weight savings could be of around 10%. In turn, this weight saving would lead to a fuel saving of the order of 20-30% without drastic changes in design. Passenger car produces on average around 150 g/km spend gasses, but by magnesium technology that uses up energy is around 100-120 g/km. Considering the large number of vehicles around, we can say that weight saving could help to keep cleaner the atmosphere and to hold the global warming better. That would be done because of weight saving lead to a significant reduction of carbon dioxide released to the air.
Magnesium is now the center of attention for the United States Automotive Materials Partnership (USAMP). This USCAR initiative investigates ways to develop a family car that can attain 2.9 L/100 km (80 mpg). The $10 million project involves the U. S. government, automakers, suppliers, universities, and national laboratories. Australian Magnesium Company announced a strategic alliance with German-based VAW Aluminum, AG to assess the potential for the production of a magnesium engine block.
Many magnesium advantages are used in world economic because they can't be realized using other materials and comparable manufacturing processes. When the die casting process reaches such a high state of perfection, there is a tendency for some to think of future progress in terms of purification. Such thinking isn't always true. There are many things that have to be done to realize all these suggestions and aims - bigger and better casting machines, improved finishing techniques, casting of metals that have not yet been practical and so on. Mostly the die casters are aware that magnesium is expensive, corrosive, and a fire hazard. But mostly these thoughts are exaggerated. In order to capture new markets and increase the use of magnesium die castings, the leading producers as well as the material design engineers should be educated at the end-user level. So, people have to know all positive advantages of die casting in magnesium, looking at the major economic advantages over other materials and similar processes.
Some major advantages over other materials are:
Some other magnesium advantages include points like:
- Magnesium alloys have
high fluidity, which allows casting of complex and thin-walled parts (e.g.
2mm, or 0.08in).
- Magnesium has a low volumetric specific heat compared with aluminum and zinc, which means that magnesium castings cool more quickly, allowing faster cycle times and reducing die wear.
- Low density of magnesium show that gate pressures can be achieved at moderate pressures.
- Iron in the dies has very low solubility in liquid magnesium alloys, which reduces the sticking tendency encountered with aluminum. In addition, magnesium die casting alloys contain less heat per volume. As a result of these two factors, dies last two to three times longer than with aluminum.
- Dimensional stability of magnesium alloys permit structures to be made in one piece rather than assembled from several components. Among the benefits:
- Homogeneous design
- Improved reliability
- Fewer joints, parts and fasteners
- Lower assembly costs
- Less dunnage and scrap
- Lower intangible costs
- Improved warehousing
- Parts consolidation also provides for design simplification.
- Design Simplification. Component consolidation allows for single shell, or monocoque, design. The principal advantage is simplified construction. The benefits of using thick-gage magnesium instead of a thin-gage construction requiring separate stiffening components are:
- Greater ruggedness for longer life and fewer repairs
- Greater stiffness
- Better denting resistance
- Greater cubic capacity for same overall size (no extra ribs needed)
- Greater cubic capacity per unit of structure weight
- Smoother surface for improved appearance and aerodynamics
- Superior Dimensional Stability. Magnesium die castings exhibit consistent and predictable shrinkage rates during solidification. Magnesium parts eject from the die with minimum distortion and casting stress.
- Higher Production Speeds. Magnesium's extremely low heat content produces fast chilling of molten metal. The low heat content of magnesium means less energy is required to reach casting temperature than for an equal amount of aluminum. In fact, depending on their size and configuration, some magnesium parts can be die cast up to 50% faster than the same parts in aluminum.
- Longer Die Life. Magnesium's low heat content and low affinity for iron reduce the effect of thermal fatigue and die erosion. Dies last as much as two to three times longer, than those experienced with aluminum.