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Title: 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.
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Resource Relation:
Conference: International Magnesium Association's 72nd Annual World Magnesium Conference
Research Org:
General Motors LLC
Sponsoring Org:
USDOE Office of Energy Efficiency and Renewable Energy (EERE), Advanced Manufacturing Office (EE-5A)
Contributing Orgs:
Meridian Lightweight Technologies, General Motors LLC, The Ohio State University
Country of Publication:
United States
36 MATERIALS SCIENCE; Magnesium; die casting; manufacturing; lightweight; automotive; door