Recent developments in high-pressure die-cast magnesium alloys for automotive and future applications

The use of magnesium alloy high pressure die cast (HPDC) components for structural applications, especially in the automotive and transportation industries, where weight reduction is of a great concern, is increasing. As new applications are developing and existing applications are becoming more complex, there is a need for improved properties from magnesium HPDC alloys. This paper reviews the recent developments in HPDC magnesium alloys for transportation applications. Compared to the conventional HPDC magnesium alloys, i.e. AZ91D, AM50A/AM60B and AE44, these new alloys have one or more of the following properties: higher strength, higher ductility, superior high-temperature properties or higher thermal conductivities. In this work, characteristics which are important in product manufacturing or product performance will be evaluated and discussed, including die castability of powertrain component or thin-walled structural component, mechanical properties at elevated temperatures and ductility. Results indicate that these alloys have great potentials to be added to the current magnesium HPDC alloy family and being used in actual automotive and other transport applications.