Mass production of large thin-walled castings such as lift gates may introduce additional challenges compared with a typical casting in terms of tool design and casting process design. Proper die thermal management yields a high production rate and optimal quality parts as well as improved die life. The geometry of parts, physical properties of alloys, feeding system design and process parameters all have their own influence on the overall success of part production. In this paper, some of the major challenges and recommendations to consider during the tool and casting process design for FAW Lift Gate, a large thin-walled casting, are highlighted.

The Mg₁₇Al₁₂ β-phase is highly influential to the performance of magnesium-aluminum high-pressure die-casting alloys. Numerous studies have investigated the effect of this phase on the room temperature and elevated-temperature mechanical properties as well as the corrosion, flammability, thermal conductivity and castability performance. This work summarizes the results of these works, as well as the studies that describe control of the Mg₁₇Al₁₂-phase through alloying additions that modify the microstructure and resulting alloy performance. The results of this work can be used as a basis for the development of alloying additions that enable modifications to the performance of high-pressure die-cast magnesium-aluminum-based alloys.

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.