CASTING INNOVATIONS
GM Saves Weight With Magnesium Squeeze Casting Te GM China Ad-
vanced Technical Center (ATC) in Shanghai an- nounced the operation of its vertical squeeze casting (VSC) machine—the first in the world designed for developing next-generation magnesium castings. Tis achievement marks a break- through in lightweight ma- terials research by General Motors Co., Detroit. Te VSC machine was jointly de-
“Te benefits of squeeze castings also mean we can use castings to replace some forged components at lower costs.”—Jeff Wang
Te system is designed to im-
signed by GM’s lightweight materials research teams in Detroit and Shang- hai. Te new technology will make it easier to manufacture vehicle parts from magnesium, which is lighter than aluminum and helps improve a ve- hicle’s fuel economy. Magnesium alloy is the lightest metal currently available for the mass production of automo- tive materials. A part made from magnesium alloy is 30% lighter than a part made from aluminum alloy. It is estimated that a vehicle’s fuel economy will improve by 7% for every 331-lb. (150kg) reduction in weight.
prove component integrity through the application of high squeeze pres- sure during the casting process. Its fully enclosed magnesium melting and transferring systems can signifi- cantly improve the performance and quality of the castings. Te system isolates the molten surface of the magnesium from oxygen, which could produce oxide inclusions. The novel capabilities will lead
to more opportunities to convert other fabricated parts to the new casting process. “Te expected benefits of squeeze
castings also mean we can use castings to replace some forged components at lower costs,” said Jeff Wang, GM China Science Lab’s group manager, ma- terials research. “Our efforts to promote magnesium alloy applica- tions will not only meet customers’ needs for better fuel economy and better performance at an afford-
able cost, but also take advantage of the ready availability of magnesium in China,” Wang said. China currently accounts for more than 80% of the world’s magnesium output. Te VSC machine is located in
the micro-foundry and formability lab, part of the Advanced Materials Lab in the GM China Advanced Technical Center (ATC). Opened in 2011 with a focus on develop- ing cost-effective lightweighting technologies, the ATC has mechani- cal testing facilities, microstructure analysis, metallography and electro- chemistry labs.
The vertical squeeze casting system was designed by GM research teams in Detroit and Shanghai. 44 | MODERN CASTING June 2014
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