Magnesium Die Casting

International Summer School on High-Integrity Die Castings

28 Jul.-1 Aug., 2008, WPI, Worcester, USA

K. U. Kainer, Z. Zhen, Y. Huang, N. Hort

Magnesium Innovation Centre MagIC, GKSS Forschungszentrum
Geesthacht GmbH

PAGE 1
 Challenges for Magnesium R&D

Sheets, outside
 Magnesium for consumer products
 Early application in 1940’s and 1960’s Sheets, inside
(VW Beetle)
 Revival since 1990’s; main application

Challenge
Extrusions
areas:
– Automotive (see figure) Thixo-/ foring parts
for chassis
– 3C industries
computer, Complex thin-walled
communication, casting parts for body
consumer electronics Casting for high
thermal and
mechanical load

Casting

Time

Friedrich H., Schumann S., Proc. of the Second Israeli International Conference (2000): 9–18.
PAGE 2
 Magnesium in Automotive Today

Global emissions standards are getting more stringent

Reduced emissions ~ Cleaner Air

Chart courtesy of CSM Worldwide
PAGE 3
 Weight Savings: Materials

Steering Column
Support
Engine V-4 Mg: 1,4 kg Tailgate
Mg: 16 kg Steel: 2,3 kg Mg: 3,2 kg
Al: 22 kg 40 % Al: 5,5 kg
Fe/Steel: 60 kg 42 %
22 - 73 %
Seat frame
Mg: 1,8 kg
Steel: 5 kg
64 %
Wheel case
Mg: 11,4 kg Inner Door
Steel: 15,6 kg Steering Column Mg: 5,4 kg
28 % Mg: 0,9 kg Al: 8,2 kg
Steel: 1,4 kg 33 %
33 %
Quelle: www.magnesium.com

PAGE 4
 Potential Weight Savings

Component
Currently used Additional Potential Use of Mg
on e.g. VW / short term medium term long term
Audi vehicles < 5 years > 5 years > 10 years

Power Train 18 kg 24-29 kg 38-49 kg

4 kg 12-16 kg 14-20 kg

3 kg 23-37 kg 31-49 kg 46-69 kg

4-6 kg 34-40 kg

59-82 kg 87-130 kg 132-184 kg

Grand Total 25 kg

After Volkswagen AG, K-EFWM/Dr. Schumann/Sinomag11.2002

PAGE 5
 Use of Magnesium in the Past

1939 Before WW II

1924

1941
1939
After WW II

1952

1995 1946-1978
PAGE 6
 Magnesium Applications Today

Interior Parts Interior Parts

Seat Components Sunroof Components
Instrument Panels Mirror Frames
Knee Bolsters Headlight Retainers
Inner Door Frames
Steering Column Comp.
Steering Wheels Drive train Parts
Brake & Clutch Pedal Manual Transmission Housings
Brackets 4 WD Transfer Case
Airbag Retainers
Brackets
Radio Frames
Radio and HVAC Covers

Engine Parts
Crankcase
Cylinder head Covers
Intake Manifolds
Drive Brackets
Electrical Connectors
Engine Cradle
Oil pans

PAGE 7
 Magnesium Applications Today: High
Pressure Die Casting

PAGE 8
 Temperatures for Power Train Use

suspension,
crank shaft engine block
T > 200 °C

piston
T > 250 °C

fan, gaskets
T < 100 °C

filter boxes
T = 150-200 °C
ignition plug, gear box housing
catalyst T < 175 °C
source: Volkswagen AG

PAGE 9
 Applications in Power Train: High
Pressure Die Casting

PAGE 10
 Forecast High Pressure Die Casting

Casting ,000 tons

Source: Hydro Magnesium intern: Probability Forecast

*) China domestic demand on die casting is included as of 2004
PAGE 11
 Forecast: Applications HPDC-Parts

80
Powertrain
Structural Components

60
[m etric ktons]

40

20

0
2005 2006 2007 2008 2009 2010
Year
Source:D. Webb http//www.intlmag.org
PAGE 12
 Use of Magnesium Alloys

• Casting
- Die casting (AZ, AS, AE, AM)
- Gravity casting (AZ, K, ZK, ZE, EZ, QE, WE)
- Squeeze casting (AZ, AS, AE, AM, K, ZK, ZE, EZ, QE)
- Semi-solid (AZ, AS, AE, AM)
• Extrusion (AZ31, AZ61, AZ80, WE54, WE43)
• Rolling (AZ31, HK31, HM21, ZK60)
• Forging (AZ31, AZ60, AZ80, ZK)
• Corrosion protection
• Welding

PAGE 13
 Magnesium Alloy Systems

• AZ (Mg-Al-Zn) • AE (Mg-Al-SE)
• good room temperature • AJ (Mg-Al-Sr)
properties
• small properties at elevated • MRI (Mg-Al-Mn-Ca-RE)
temperatures • good properties at elevated
• low ductility temperatures
• good creep resistance
• AM (Mg-Al-Mn) • constricted castability
• better ductility
• moderate room temperature
properties
• constricted castability
• AS (Mg-Al-Si)
• better strength
• improved creep resistance
• constricted castability
PAGE 14
 Magnesium Casting Alloys

• Die casting
- AZ, AS, AE, AM
• Gravity casting
- AZ, K, ZK, ZE, EZ, QE, WE
• Squeeze casting
- AZ, AS, AE, AM, K, ZK, ZE, EZ, QE
• Semi-solid
- AZ, AS, AE, AM

PAGE 15
 Patents/Modifications for Pressure Die
Cast Magnesium Alloys

Chemical Composition
Year/
Originator Al Zn Mn SE Ca others

1994 Nissan/Ube 1.5-10 <2 0.25-5.5

1996 MEL < 0.1 0-0.4 0-0.5 0.05 0-1

1996 Hyundai 5.3-10 0.7-6.0 0.4-5 Si

1996 ITM Inc. 2-6 0.1-0.8

1996 Noranda 4.9 0.26-0.30 1.74-1.94 Sr

4.7-4.9 0.27-0.29 1.23-1.35 Sr

1997 Honda 4.5-10 4.5- 0.2-1 1-3 0.1-3

6 0.2-1 1-3 1.2-2.2

1997 Mazda 2-6 0.5-4

1997 IMRA America 2-9 6-1 0.2-0.5 0.1-2.0
1997 Hyundai 5.3-10 0.7-6.0 0.15-10 0.5-5 Si
1999 VW/DSM 6-9 0.7-0.9 0.18-0.37 0.15-0.92 0.45-1.1 0.03-0.11 Sr

2000 Norsk Hydro 1.9-2.5 0.25 0.05-0.15 0.06-0.25 0.7-1.2 Si

Source: Pekgüleryüz, 2000, King, 1998, Norsk Hydro, 2003

PAGE 16
 VW Objectives For HPDC High
Temperature Magnesium Alloys

• Room temperature characteristics at least as good

as AZ91.
• Elevated strength better than AZ91 beyond 120ºC.
• Minimum creep rate better than AE42.
• Castability similar to AZ91.
• Corrosion resistance similar to HP AZ91.
• Cost ≤ 1.2 x AZ91

PAGE 17
 Castability of Mg-Al-Zn Alloys

alloy-
groups
AZ-Base 1
AZ-Base 2
ZA-Base

castable
difficult

Zn-content (wt.-%)
Source: Foerster

PAGE 18
 Castability and Creep Resistance

180 1: AZ91
°C
10 2: AS21X
8 9 3: MRI153M
7 4: AJ62X
6 5: AE42
Resistance

5 4 3 6: AJ52X
Creep

2 7: ACM522
8: AX52J
150 1 9: MRI230D
°C
10: AM-HP2
Castabilit
Source: Aghion et al., Dunlop et.
PAGE 19
y
Al.
 Die Casting of Magnesium Alloys

• Filling time 30 % shorter compared to Al

• Life time of tools higher
• Ingate speed appr. 90-100m s-1
• Ingate thickness > 0.8 mm
• Temperature of the die: 220-240 ºC
• Die casting alloys
- Hot chamber: AZ, AM
- Cold chamber: AZ, AM, AE, AS

• Not all Mg-alloys can be used for die casting!!

PAGE 20
 Illustration of die casting process

Source: www.ekkinc.com
PAGE 21
 Cold Chamber Die Casting Process

moving platen
fixed platen moving die
part
ejector

ejector die

plunger

chamber

PAGE 22
 Hot Chamber Die Casting Process

hydraulic closing die

die
piston

melt

chamber

PAGE 23
 HPDC Unit

Source: www.rauch-ft.com

PAGE 24
 HPDC and Vacuum HPDC

PAGE 25
 Cover Gases

Unsolved status in the EU:

Fluor containing gases are likely to be abandonned.
Cover gas components:
SF6, SO2, R134a (HFC134a)
New protective gases:
Novec 612, Fluorokethone, Hydro-Fluorether

Global warming potential (GWP):

FK < HFC134a < SF6
0,05% 5% 100%

PAGE 26
 Relationship Between Magnesium Die Casting
Defects And Processing Parameters

Metal Metal Die Gating Die vent Die lubricant Metal Ejection Casting rate
velocity Pressure Temperature system Temperature defect

Incomplete
filing
● ● ● ● ● ● ●
Cold shuts
● ●
Pores
● ● ● ●
Gas bubbles

Shrinks
● ●
Blisters
● ● ●
Flow marks
● ● ● ● ●
Surface
Swirls
● ●
Hot cracks
● ● ● ●
Cracks/fract
ures
● ● ●
Deformation
● ●

PAGE 27
 Quality Control

Alleviation of pre-solidification in the shot

sleeve:
• Reduce the heat transfer from the melt to the sleeve wall
by insulating the inner sleeve wall.
• Reduce the heat conductivity in the sleeve wall.
• Reduce the heat transfer by maintaining a higher temperature
in the sleeve wall.

Source: Gjestland et al. Adv Eng Mater,

2007
PAGE 28
 Microstructure

Secondary dendrite arm spacing and grain size as a function of

solidification rate in AZ91D

Source: Gjestland et al. Adv Eng Mater,

2007
PAGE 29
 Creep Properties Of Mg-al-ca Alloy Produced
By Die Cast, Squeeze Cast And Gravity Cast

Die cast
Squeeze cast
Die cast
Source: Zhu et al, Mater.Sci.Eng.A,2008
PAGE 30
 Numerical Simulation Methods

Finite Difference Method (FDM) and Finite Element Method (FEM)

FDM is easy on programming and gives result with reasonable accuracy, while FEM
shows advantages on simulating complex and thin-wall castings, due to its better
geometry replication.

FEM FDM

Thin-wall casting geometry modeled by using FEM and FDM methods

Source: Marty McLaughlin, www.ekkinc.com

PAGE 31
 Mold Filling Simulation Of Hot-chamber
Diecast AM60B

Filling time:
11ms

Cast temp.:
650oC

Software:
self-developed
3D FDM
program

Mold filling simulation results of diecast AM60B alloy, showing that the melt enters a cylindrical bar
in the way of a jet and is “bounced” backward along the wall when striking the filled part

Source: Li and Zhou, Materials Technology, 2003

PAGE 32
 A Mold Filling Simulation Case

Source: Song and Xu, North Hengli Sci. and Tech Co.
PAGE 33
Ltd.
 Solidification Simulation Of HPDC
Magnesium Alloys

Source: Song and Xu, North Hengli Sci. and Tech Co.
Ltd.PAGE 34
 Flow Simulation Within Shot Sleeve

Magnesium die casting part is usually very thin and the

heat capacity (combining the specific heat and latent
heat of fusion) of magnesium is small compared with that
of aluminum. Therefore, magnesium die castings solidify
during the die filling more remarkably than aluminium die
castings. It also indicates that the accuracy of mold filling
simulation for magnesium die castings is more significant
than that of aluminium alloys. To further improve the
accuracy of flow simulation, recently, melt motion within
shot sleeve had been integrated into the mold filling
simulation for magnesium alloys.

Source: www.ekkinc.com
PAGE 35
 Solidification Simulation Of Low Pressure Die
Cast Magnesium Wheel

Source: NERC-LAF, Shanghai Jiaotong

Uni.PAGE 36
 Solidification Simulation Of Low Pressure Die
Cast Wheel

Source: NERC-LAF, Shanghai Jiaotong

PAGE 37
Uni.
 Solidification Simulation Of Low Pressure Die
Cast Engine Block

Source: NERC-LAF, Shanghai Jiaotong

PAGE 38
Uni.
 Microstrutural Simulation Of Die Cast AM50

Microstructure of die cast AM50 simulated by using a 2D Cellular Automaton based

model coupling with macro heat transfer calculation

Source: Fu et al, Mater.Sci.Forum, 2008

PAGE 39
 Magnesium Recycling

• Driving force is saving energy:

- 35 kWh/kg for prime-production
- 3 kWh/kg for remelting magnesium-scrap
• Prime scrap: casting alloys, crap of production
• Old scrap: alloys, partly polluted
• Alloy mix
- Definition of recycling alloys
- Base alloy system
- Influence of alloying elements, impurities on property
profile

PAGE 40
 Recycling Alloys

PAGE 41
 Quelle: IMA, MEL, Hydro Magnesium
2007
2006
2005
2004
2003
Secondary Magnesium

2002
2001
2000
1999
1998
1997
1996
1995
1994
1993
1992
1991

0
200

150

100

50

PAGE 42
 New Secondary Alloy

Composition and microstructure of the new secondary alloy compared to AZ91D

Alloy Al Zn Mn Si Cu Fe Ni
AZ91D 8.75 0.67 0.2 0.054 0.008 0.0022 0.0006
AZC1231 11.7 3.04 0.48 0.39 0.47 0.0087 0.0032

AZ91D (600-800 µm) AZC1231 (~100 µm)

PAGE 43
 Corrosion Properties

Corrosion properties of AZ91D and AZC1231 determined in various corrosion tests

(gravity die casting except * HPDC housing)

Corrosion test condition AZ91D AZC1231

Pot.dyn. polarisation 0.43 ± 0.04 1.81 ± 0.59
(after 1h in 5%NaCl, pH11) mm/year mm/year
Lin. polarisation resistance 247 cm2 80 cm2
(after 24h in 5%NaCl, pH11)
Impedance 263 cm2 149 cm2
(after 36h in 3.5%NaCl, pH7)
Saltspray 1.07 ± 0.23 0.99 ± 0.58
(after 48h in 5%NaCl, pH7) mm/year mm/year
Immersion* 1.49 1.42 ± 0.26
(average after 400 h in 3.5%NaCl, pH6) mm/year mm/year

PAGE 44
 Mechanical Properties

Comparison of the mechanical properties of the new alloy AZC1231 and AZ91D

Property AZ91 AZC1231

Hardness (HV5)** 83,2 ± 3,3 104,9 ± 2,8
Friction coefficient** 0.27 0.23
Wear volume** (mm3/N/m) 11.5 * 10-4 6.7 * 10-4
Rm* (MPa) 263 ± 14 246 ± 17

Rp* (MPa) 198 ± 15 187 ± 27

A5* (%) 2.1 ± 0.5 0.7 ± 0.5

Creep rate ** (s-1) 4,38 * 10-8 1,74 * 10-8
SCC threshold stress*** (MPa) 90 130

* HPDC housing, ** HPDC test specimen, *** gravity die cast

PAGE 45
 Casting Properties

Helix casting experiments* (700°C melt temperature, release agent Demotex S)

Giesserei 94, Nr. 11 (2007), S.20-33

* C. Scharf, P. Živanovic, A. Ditze, K. Horny, G. Franke, C. Blawert, K.U. Kainer, E. Morales,
Thelix angle filled length completely filled
[°C] [°] of the helix length of the helix
[cm] [cm]
AZ91D 159.0 256.8 48.6 23.0
± 5.7 ± 36.1 ± 7.4 ± 1.8
AZC1231 158.8 408.8 66.1 39.5
± 2.5 ± 28.4 ± 5.6 ± 6.0
Better casting properties compared to AZ91D,
thus no limitations in the possible casting processes

gravity die casting NRC HPDC

PAGE 46
 Research into the Industrial Use

Gravity die casting ingot ingot housing housing

6 kg melt volume (Lab) (AZ91D) (AZC) (AZ91D) (AZC)
Rm (MPa) 198 189 258 250

Rp0,2 (MPa) 81 152 187 187

A5 (%) 5,6 0,5 2,8 1,4

25 mm
CRsalt spray 1 1 2,5 5
(mm/year)
HPDC housing
1000 kg melt volume (Industry)
AZC secondary alloy has similar properties
(casting behaviour, strength and corrosion
resistance) compared to AZ91D
Patent application:
Ditze, A. Scharf, C., Blawert, C., Kainer, K. U., Morales, G.E.D.:
250 mm Magnesiumsekundärlegierung. DE 10 2005 033835 A1, 2005.
Ditze, A. Scharf, C., Blawert, C., Kainer, K. U., Morales, G. E. D.:
Magnesium Alloy. WO 2007/009435 A1, 2006.

PAGE 47
Source: Institut fuer Fahrzeugkonzepte,
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DLR
Source: Institut fuer Fahrzeugkonzepte,
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DLR
Source: Institut fuer Fahrzeugkonzepte,
PAGE 50
DLR
Source: Institut fuer Fahrzeugkonzepte,
PAGE 51
DLR
Source: Institut fuer Fahrzeugkonzepte,
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DLR
 Thank you for your attention!
PAGE 53