Magnesium Applications

High Pressure Die Casting
 
High pressure die casting (HPDC) is the leading process technology for the production of Mg particularly for the transportation industry. Currently the automotive industry is searching for lightweight materials for powertrain parts, which are subjected to both high temperatures and dynamic loads. Magnesium high-pressure die casting alloys are finding increasing applications in the automotive industry due to the range of their attractive properties such as high strength/stiffness to weight ratio, die Castability, damping capacity, the possibility of integrated design, etc .
Magnesium alloys are widely being used in safety related parts such as steering wheels, instrumental panels, seats and doors. For automotive powertrain applications, the alloy selection is dictated by number of requirements that include creep and corrosion performance, tensile, compressive and fatigue properties, Castability and production cost.
Until recently, the utilization of magnesium alloys in powertrain parts was not realized due to reasons mainly associated with increased magnesium cost compared with aluminum and, to great extent, with lack of suitable HPDC magnesium alloys that have characteristics that match closely those of HPDC aluminum alloys like A380.
DSM has developed MRI 153M and MRI 230D alloys, which are designated for powertrain components that are operating at temperatures up to 150°C and 200°C, respectively.
 
 
Gravity casting alloys
 
Gravity casting processes such as sand casting, permanent mold casting as well as their low pressure modifications enable the production of large components to be used mainly in the automotive and aerospace industries. Except for AZ91E alloy, all other gravity casting alloys are creep resistant alloys containing Zr and different rare earth elements.
DSM offers two high performance advanced magnesium alloys MRI 201S and MRI 202S. These alloys are well suitable for sand and gravity die casting applications and for related low-pressure alternatives. New alloys have to be used only in the T6 condition to realize the precipitation hardening mechanism and generate the optimum combination of ambient strength, ductility and creep properties. Excellent high-temperature properties of MRI201S and MRI202S alloys are attractive for designers of powertrain components in the aerospace and automotive industries.
 
 
Wrought Alloys
 
DSM is among the unique producers of wrought alloys for plastic forming processes. DSM produces wrought alloys in billet form for extrusion and forging and in slab form for rolling. These are produced in a modern direct chill casting process to ensure optimized metallurgical chemistry cleanliness and quality.