2017 Awards of Excellence & Environmental Responsibility Award Awards
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Automotive Cast Product Design Category
Commercial Cast Product Category
Process Category
Wrought Product Category
Environmental Responsibility


Automotive Cast Product Design Category

Magnesium Die Cast Side-Door Inner Panel - Part 1
General Motors
Dongguan EONTEC Co., Ltd.
EDAG Engineering

PRODUCT INFORMATION

Name of Part or Process: Magnesium die-cast door inner panel
Product Using Part: Prototype door
Function of Part: Provide strength, stiffness, mounting points
Alloy Used: AM60B

DESCRIPTION

This experimental automotive side-door inner panel was high-pressure die cast in magnesium alloy in order to reduce mass, consolidate parts, and enable fine details that cannot be achieved in sheet stampings. Variable wall thickness and extensive use of ribbing were used in order to meet strength and stiffness requirements, while maintaining light weight. Innovative cast-in features include pockets for attaching the header portion of the door, which surrounds the window glass on three sides, and rivets for attaching a module panel which holds the speaker, window regulator and pull handle. After trimming and machining, the part was coated by micro-arc oxidation and polymer electrocoating to increase corrosion resistance.

Mass: 2.7 kg
Dimensions: 1202 x 843 x 170 mm
Typical wall thickness: 2 mm
Part consolidation:

  • Inner beltline reinforcement
  • Mirror patch reinforcement
  • Hinge mount reinforcement
  • Rivets for attaching module panel
  • Forward- and aft pockets for header attachment

Coatings: micro-arc oxidation plus electrocoat

Magnesium Die Cast Side-Door Inner Panel - Part 2
General Motors
Wanfeng Meridian
The Ohio State University
EDAG Engineering

PRODUCT INFORMATION

Name of Part or Process: Magnesium die-cast door inner panel
Product Using Part: Prototype door
Function of Part: Provide strength, stiffness, mounting points
Alloy Used: AM60B

DESCRIPTION

In comparison to a conventional steel stamping design, this experimental HPDC magnesium door inner panel design achieves a reduction in mass, reduction in part count, and addition of fine detail features. The mass is only 52% of that of the stamped steel version. And 7 parts are consolidated into 1 casting. The innovative design uses variable wall thickness, ribbing, and an “S”-shaped cross section to achieve the required strength and stiffness. Blind cored holes were cast in for later use with thread-forming screws to attach a stamped aluminum outer beltline reinforcement and a pull handle support. The fully assembled door-in-white includes a stamped aluminum outer panel, and weighs 9.5 kg, that is about half the weight of the steel counterpart. Advanced modeling and thermal management techniques were used in design of the die in order to achieve fully-filled high-quality castings.

Mass: 52% of stamped steel version
Dimensions: 1209 x 1130 x 290 mm
Minimum wall thickness: 2 mm
Part consolidation:

  • Reinforcements: inner beltline, mirror patch, header, B-pillar, latch mount
  • Forward tailor-welded blank

Coatings: conversion coating plus powder coat

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Commercial Cast Product Category

Magnesium Wheel for Super-sport Motorcycle
Yamaha Motor Company
Japan Magnesium Association

PRODUCT INFORMATION

Name of Part or Process: Front & Rear Die cast Wheels for super-sport motorcyle
Product Using Part: Mass Product YZF-R1 2015 Model
Function of Part: Weight Reduction of 870g, improved design & cosmetics
Alloy Used: ASTM-AM60B

DESCRIPTION

In 2015, the new model of YZF-R1 was released and included front and rear wheels made from magnesium die cast. This was a dramatic increase of magnesium usage exceeding 10kg.

  1. Application of magnesium in our motorcycle was started in 1998.
  2. Almost all of motorcycle magnesium parts are adopted in the super-sport or sport categories. However, magnesium usage has spread year over year to other categories.
  3. Since 2008, large structural magnesium parts were manufactured in house.
  4. Recently, application of magnesium has been expanded to heat resistant alloy.
  5. Magnesium wheels not only result in weight reduction but also decreases inertia mass and improves the design.
  6. Vacuum system was chosen according to part size. If large thin parts, it is effective to stabilize the quality of over flow portion.

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Process Category

Biodegradable Magnesium Alloy for Orthopedic Application
University of Oxford
In Collaboration with U & I Corporation

PRODUCT INFORMATION

Name of Part or Process: Biodegradable Magnesium Alloy for Orthopedic Application
Product Using Part: RESOMET
Function of Part: Headless Screw, Cortex Screw and K-wire
Alloy Used: Mg-Ca-Zn Alloy

DESCRIPTION

We have overcome the current limitations and created a road map to the next generation of metallic biodegradable implant materials with the addition of completely biocompatible elements. Along with the addition of Ca, which is a biocompatible element that plays major in bone formation and remodeling, excellent material properties were achieved through the in-house built special mechanical extrusion machine. The state of the art method to synchronize the corrosion potentials of two constituent phases (Mg + Mg2Ca) with the selective doping of Zn into Mg2Ca was developed to control the corrosion rate. Furthermore, mechanical extrusion broke the connectivity of the Mg2Ca phases, which prevented continuous corrosion and the formation of a galvanic circuit that caused severe corrosion of the Mg-Ca alloy. Newly developed set of RESOMET implants have the mechanical strength, ability to stimulate bone growth and controlled slow degradation rate to be considered as an ideal candidate for biodegradable implant applications.

Working closely with major hospitals in Korea, we have performed over 200 cases of small bone fixation screws so far and the screws were approved for sale in Korea by MFDS (Ministry of Food and Drug Safety). Results of clinical tests were published on PNAS.

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Wrought Product Category

Magnesium Alloy Electric Bus Skeleton
Advanced Materials Institute, Shandong Academy of Sciences
China Magnesium Association

PRODUCT INFORMATION

Name of Part or Process: Magnesium Alloy Electric Bus Skeleton
Product Using Part: Body Skeleton Using Magnesium Alloy Extruded Profiles
Function of Part: Offers Lightweight Skeleton for Body
Alloy Used: ZTM630 and ZK61

DESCRIPTION

The world’s first lightweight magnesium alloy electric bus was produced in Shandong province. The bus is 8.3 meters long, containing 24 seats. The bus body frame is totally made up of 226Kg magnesium alloys, which is 780/110Kg lighter compared with that of steel/aluminum alloys.

A novel magnesium alloy of Mg-Zn-Sn-Mn was developed and the yield strength (YS) and ultimate strength (UTS) for as-extruded Mg-6Zn-3Sn-0.5Mn (wt.%) alloy could reach 383 MPa and 412 MPa, respectively. The yield strength (YS) and ultimate strength (UTS) for as-extruded ZK61 alloy could reach 285 MPa and 336 MPa, respectively. Nine kinds of magnesium alloy extruded profiles were used in the bus body frame. All of them were conducted with F-free and Cr-free phosphating technology to improve the corrosion resistance.

By adopting lightweight magnesium alloys, the following advantages of the electric bus were obtained: improved mileage, shorter braking distance and reduced noise.

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Environmental Responsibility

FGS Technology
Oskar Frech GmbH + Co. KG

PRODUCT INFORMATION

Name of Part or Process: FGS Technology for Magnesium Hot Chamber Die Casting
Product Using Part: Die Casting Mold, HPDC Process Controller
Function of Part: New Die Casting Process
Alloy Used: AZ91 and AM60

DESCRIPTION

The FGS technology is the consequent further development of the Hot Chamber Die Casting process with the primary target of mostly eliminating the customary runners in a die using a hot runner technique and corresponding HPDC process control.

The challenges in HPDC of non-ferrous metals are quite significant when developing a hot runner system. Using Mg alloys, which have rather high melting temperatures, this requires a specific heating technology, equipped with very good temperature control. So the precondition in HPDC is to have a powerful close-loop temperature controlled casting unit.
Due to metal casting process, the system has to be extremely robust and with excellent tightness, so it can stand functioning in operation as well as during start-up procedures, when strong thermal expansion take effect. In the HPDC process there is no possibility to put locking elements in the die, since during the die open period, formation of Magnesium oxides are possible, which will interfere proper operations.

The FGS technology has a great number of advantages, which in the above matrix. Measurements have shown that the hot runner system significantly relieves the classical temperature control of the die and the casting system. This means that the overall energy consumption is less. The electrically heated casting system requires more than 50% less than conventional heating and the FGS system reduces the energy consumption for die temperature by 11%. This energy saving is associated with a corresponding reduction in CO2 emissions during die casting. Approximately 38 t CO2 is thus avoided for casting a 320 g Mg part with an annual production of 660,000 pieces.

Thus, the FGS technology is a milestone in HPDC.

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