Development of a Thin-Wall Magnesium side door Inner Panel for Automobiles
Cast magnesium side door inner panels can provide a good combination of weight, functional, manufacturing and economical requirements. However, several challenges exist including casting technology for thin-wall part design, multi-material incompatibility and relatively low strength vs steel. A project has been initiated, supported by the US Department of Energy, to design and develop a lightweight frame-under-glass door having a thin-wall, full die-cast, magnesium inner panel. This development project is the first of its kind within North America. Phase I of the project is now complete and the 2.0mm magnesium design, through casting process enablers, has met or exceeded all stiffness requirements, with significant mass reduction and part consolidation. In addition, a corrosion mitigation strategy has been established using industry-accepted galvanic isolation methods and coating technologies.
- Research Organization:
- General Motors LLC, Detroit, MI (United States)
- Sponsoring Organization:
- USDOE Office of Energy Efficiency and Renewable Energy (EERE), Energy Efficiency Office. Advanced Manufacturing Office
- Contributing Organization:
- Meridian Lightweight Technologies, General Motors LLC, The Ohio State University
- DOE Contract Number:
- EE0005753
- OSTI ID:
- 1179778
- Report Number(s):
- DOE-GM-5753-1
- Resource Relation:
- Conference: International Magnesium Association's 72nd Annual World Magnesium Conference
- Country of Publication:
- United States
- Language:
- English
Similar Records
Design of a magnesium/aluminum door frame
Development of a Novel Magnesium Alloy for Thixomolding® of Automotive Components (Final Report)