Automotive Applications - International Magnesium Association

Automotive Applications

In the 1920s magnesium began to make an appearance in the automotive industry. The light weight metal began to be used in racing cars to add to their competitive edge. About a decade later, magnesium began to be used in commercial vehicles such as the Volkswagen Beetle which contained about 20kg (44.09lbs) of the material. The interest in magnesium use in automotive applications has increased over the past ten years in response to the increasing environmental and legislative influences. Fuel efficiency, increased performance and sustainability are top-of-mind issues.

BMW-6-cylinder-block
By 160SX [160SX (talk)'s file] [GFDL or CC-BY-SA-3.0-2.5-2.0-1.0] via Wikimedia Commons

The use of magnesium in vehicles can, and does, lower overall weight and improve each of these conditions. Many large automotive companies have already replaced steel and aluminum with magnesium in various parts of their products. Audi, Daimler (Mercedes-Benz), Ford, Jaguar, Fiat and Kia Motors Corporation are just a few of these companies. Magnesium is currently being used in gearbox, front end and IP beams, steering column and driver’s air bag housings as well as in steering wheels, seat frames and fuel tank covers.

The usage of magnesium in automotive applications can provide more than just a weight savings. For a number of years, the desire to identify challenges, solutions, and opportunities regarding the use of magnesium in vehicles has been growing. Magnesium usage on the front end of a vehicle provides not just a lower overall mass for the car, but also allows for the shifting of the center of gravity towards the rear of the car improving handling and turning capabilities. In addition, frequencies that reduce vibration and overall noise can be achieved through the tuning of magnesium parts. Steel components in vehicles can be replaced by a single cast piece of magnesium adding to the strength of the material and allowing for housings to be cast into place. This castability also requires less tooling and gauges which lowers manufacturing cost.

magnesium in automotive applications
Image: Chicago White Metal

3D Demonstrator

Mg Automotive Applications Screen Animation
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Member Spotlight

Name of Part: Cross Car Beam
Product Using Part: Jaguar Land Rover Defender Cockpit
Function: Bracket parts with visible A surface in the instrumental panel
Alloy Used: AM60

Visible Magnesium Surface:
GF Finishers Refining Jaguar Land Rover’s (JLR) New Defender Cockpit

On the market since spring 2020, the modern and technical interior design of the JLR Defender showcases casting innovation and great success in the field of Magnesium structural parts.

Defender: Comeback of an icon
In 2019, almost three years after the production stop of the traditional JLR Defender - known from the US TV series Daktari - GF Casting Solutions AG received the honor of developing components for the new version of the off-road legend. Thanks to strong teamwork and many years of know-how, five lightweight Magnesium components were created which, together with the cross car beam, form the basis of the instrument panel. Thanks to the preservation of the angular basic shape and a new, contemporary design, both die-hard fans as well as new customers can enjoy the traditional vehicle.

Bracket parts with visible A surface in the instrument panel
Providing off-road look and clear geometries, the new cockpit with a high percentage of Magnesium surfaces is a role model for the usage of structural parts in Magnesium high-pressure die casting. With the set of five lightweight Magnesium parts in addition to the Magnesium Cross Car Beam, GF Casting Solutions has created a complete structural solution which is not only light and stable, but noble. All the visible Magnesium parts show A surface quality in the instrument panel – the cover plate at the passenger side even features the Defender lettering integrated into the casting.

The very high surface quality requirements can only be met through long-standing experience in Magnesium casting and very reliable manufacturing processes. Altogether, the five components are building the base for the instrument console. Before the set of Magnesium components leaves its home base at GF Casting Solutions Altenmarkt in Austria, they are coated and assembled.

Cross Car Beam: Heart of the cockpit’s structure
In comparison to conventional solutions, the one-piece cast Cross Car Beam – which belongs to the crash-relevant parts in the cockpit – replaces up to 10 individual components. Further components inside the cockpit such as head-up display, air conditioning, ventilation channels, knee air bag, glove compartment and steering console are attached to the cross car beam and its Magnesium finishers. For the final assembly, the 1.50 meter component is simply screwed to a few attachment points like for example the A pillar and the center console.

Extended casting competence: High-quality and complex tooling
The manufacturing process of the five bracket parts requires complex and up to 2-cavity die-casting tools and high-class trimming competence to guarantee the high quality of the component’s surface. The A surface area in the tool is therefore surface treated. After the casting process, the Magnesium high-pressure die casting parts are powder coated with very small tolerances and very high requirements. Besides, the Magnesium offers high functional integration and meets all requirements of safety at an extremely low weight.