Potential Magnesium Alloys for High Temperature Die Cast Automotive Applications: A Review

Abstract Magnesium, as a lightweight construction material, has rapidly grown its applications in the automotive industry since the early 1990s. To maximize the weight reduction of vehicles by lightweight magnesium alloys in the coming years, the use of newly developed high-temperature magnesium alloys is expected to increase significantly, particularly in the powertrain applications where the creep resistance is always required. This article reviews recent developments of the creep-resistant magnesium alloys. Fundamental aspects of the creep deformation theory and mechanisms are described. The metallurgical principles for designing the creep-resistant alloys are highlighted. The creep behavior of magnesium and its conventional alloys is discussed based on some microstructure analyses. The mechanical properties, microstructure, and manufacturability of the newly developed creep-resistant magnesium alloys are also overviewed. The further research and development work is outlined in terms of developing magnesium alloys for some potential and value-added automotive applications. Acknowledgments The authors want to thank the Natural Sciences and Engineering Research Council of Canada and the University of Windsor for supporting this work. The work presented is also part of the Magnesium Manufacturing & Product Development group projects in the Manufacturing Systems Department, Ford Research Laboratory, Ford Motor Company.