USCAR Consortium Begins Work on Magnesium Project

    Structural Cast Magnesium Research Could Lead to Reduced CO2 Emissions

    SOUTHFIELD, Mich., May 29 The United States Automotive
Materials Partnership (USAMP-AMD), as part of the United States Council for
Automotive Research (USCAR), recently began a new Structural Cast Magnesium
Development (SCMD) project that will focus on resolving critical issues that
limit the large-scale application of structural cast magnesium castings in
automotive components.  Project Chairman Richard Osborne, of General Motors
Corp., indicated the 5-year $10M project activities "will focus on developing
the technology necessary to cast and implement a front cast magnesium
structural cradle."
    The choice of a chassis component provides many stretch goal challenges
for the project team to overcome.  Key manufacturing issues include: the
production of high integrity castings (high-pressure die, semisolid, low
pressure, squeeze, etc.) and appropriate joining methods.  Harsh service
environments create significant material challenges including:
erosion/corrosion issues and stress-relaxation concerns.
    The objectives of the SCMD project are:
    *  Improve understanding of cast magnesium alloys;
    *  Develop a cost model that compares cast magnesium chassis component
cost to alternative materials and processing techniques;
    *  Provide comprehensive database and design guidelines;
    *  Improve cast component integrity;
    *  Identify and/or develop methods to improve corrosion resistance;
    *  Develop accurate Failure Mode and Effects Analysis (FMEA) for design
and manufacturing of chassis-type components;
    *  Improve dissimilar material joining technologies; and
    *  Transfer knowledge and lessons learned to industry.

    This project, sponsored cooperatively through USAMP-AMD and the Department
of Energy through a Cooperative Research And Development Agreement (CRADA),
involves a number of research entities:
    *  National Laboratories: Lawrence Livermore (LLNL), Oak Ridge (ORNL), and
Sandia (SNL)
    *  General Motors, Ford, and DaimlerChrysler
    *  More than 35 light metal suppliers
    *  Academia: University of Windsor, Georgia Institute of Technology,
Alfred University

    Osborne indicated there is a multitude of benefits to be gained from this
research.  "We anticipate successful completion of this CRADA will lead to
positive applications, both tangible and intangible," he said.
    For instance, vehicle mass savings for ground and air transportation
leading to a reduction in fuel consumption and emissions, increased
recyclability, and less dependence on foreign oil.  Automakers in the United
States are under increasing pressure to reduce CO2 emissions and increase
federal Corporate Average Fuel Economy (CAFE) standards.  The ability to
significantly increase magnesium usage could help the auto industry meet
future CAFE targets, and reduce noncompliance penalties.
    The North American auto industry currently uses approximately 70,000MT of
magnesium/year, about 3.5 Kg per vehicle.  Cast magnesium structures have the
potential to reduce 100Kg of vehicle mass, which could reduce emissions by 5%
and increase fuel economy by about 1.0 mpg.
    This magnesium project comes on the heels of a successful, 5-year ($10M)
cast light metal program that focused primarily on cast aluminum research and
was recently completed by the same team.
    USAMP functions under the umbrella of USCAR -- a cooperative of
DaimlerChrysler, Ford and GM established in 1992.  The purpose of USCAR is to
assist the domestic auto industry in facilitating pre-competitive research.