The new technology will make it easier to manufacture vehicle parts from magnesium, which is the lightest metal currently available for the mass production of automotive materials. A part made from magnesium alloy is 30% lighter than a part made from aluminum alloy. GM estimates a vehicle's fuel economy will improve 7% for every 150-kilogram reduction in weight.
The VSC machine was jointly designed by GM’s lightweight materials research teams in Detroit and Shanghai. It was built in collaboration with an equipment manufacturer in China. Designed to improve casting integrity through the application of high squeeze pressure during the casting process, its fully enclosed magnesium melting and transferring system can significantly improve the performance and quality of the castings. It maintains the molten metal surface essentially isolated from oxygen, which would otherwise produce oxide inclusions.
“The expected benefits of squeeze castings also mean we can use castings to replace some forged components at lower cost,” said Jeff Wang, lab group manager for the materials research team at GM China Science Lab. "Our efforts to promote magnesium alloy applications will not only meet customers' needs for better fuel economy and better performance at an affordable cost, but also take advantage of the ready availability of magnesium in China." China now accounts for more than 80 percent of global magnesium output.
