Progress and prospects in Mg-alloy super-sized high pressure die casting for automotive structural components

Since the introduction of Tesla’s Giga-Casting process, the automotive industry has widely accepted the concept of super-sized structural components due to their significant potential for enhancing the light-weighting of both electric and internal combustion engine vehicles. These super-sized components can be further lightened by using Mg alloys because of their exceptional lightweight characteristics, with a density only two-thirds that of aluminium alloys and one-fourth that of steel. This outstanding attribute offers the attractive prospect of achieving significant weight reduction without compromising structural integrity. This review examines studies on the Mg-alloy High-Pressure Die Casting (HPDC) process, providing insights into the future prospects of incorporating Mg alloys into super-sized automotive HPDC components.