Lightweight Design and Manufacturing of High-Pressure Die-Cast Magnesium Alloy Components for Automotive Applications: A Comprehensive Review

Xingchu Xiang; Junchi Ma; Rui Hua

doi:10.54097/hvascw12

Authors

Xingchu Xiang
Junchi Ma
Rui Hua

DOI:

https://doi.org/10.54097/hvascw12

Keywords:

Magnesium alloys; high-pressure die casting; automotive light-weighting; structural applications.

Abstract

The imperative for vehicle mass reduction, driven by increasingly stringent greenhouse gas emission regulations and the rapid proliferation of electric vehicles, has positioned magnesium (Mg) alloys as compelling candidates for structural automotive applications. With a density of merely 1.74 g/cm³ — approximately two-thirds that of aluminium and one-quarter that of steel — Mg alloys offer an unparalleled weight advantage among engineering metals. High-pressure die casting (HPDC) remains the dominant manufacturing route for automotive Mg components, accounting for approximately 90% of total production volume. This review systematically synthesizes findings from peer-reviewed publications to establish a comprehensive knowledge framework encompassing alloy systems, vehicular applications, and original equipment manufacturer (OEM) development practices. In the domain of alloy selection, the Mg-Al-Zn system (principally AZ91) provides superior castability and strength for non-safety-critical components, whereas the Mg-Al-Mn system (AM50/AM60) delivers the requisite balance of strength and ductility for crash-relevant structures such as seat frames and instrument panel beams. Recent advances in Mg-Al-Sn (AT72) and Mg-Al-Zn-Mn alloy families demonstrate promising avenues for tailored strength–ductility combinations. With respect to vehicular deployment, Mg die castings have been successfully implemented across body systems (door inners, front-end carriers, closure panels), achieving mass reductions of 40–50%, and chassis systems (wheels, steering columns, subframes). A detailed case study of the Mg alloy seat frame (MASF) forward-development programme at Changan Automobile illustrates the complete design–simulation–process–verification chain, yielding a 9.88 kg seat frame representing a 24.6% mass reduction with process yields exceeding 90%. The challenges and future prospects for expanded automotive Mg adoption are critically assessed.

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