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Magnesium alloys are well-known for being the lightest structural alloys [1].

They are made of magnesium, the lightest structural metal, mixed with other metal elements to improve the physical properties. These elements include manganese, aluminium, zinc, silicon, copper, zirconium, and rare-earth metals [2].

Some of magnesium’s favourable properties include low specific gravity and a high strength-to-weight ratio. As a result, the material lends itself to a range of automotive, aerospace, industrial, electronic, biomedical, and commercial applications

Properties and advantages Applications

Magnesium alloys cover a wide array of applications, from automotive and aerospace applications to electronic and biomedical uses.

Structural applications Automotive, aerospace, industrial, and commercial applications are examples of structural applications. The advantage of magnesium alloys to be used in such applications is their light weight, high strength-to-weight ratio, high stiffness-to-weight ratio, castability, machinability, and great damping [4].

Automotive: support brackets for brakes and clutch, housing for transmission

Aerospace: landing wheels, helicopter rotor fittings, gearbox housings

Industrial: high-speed operating machinery, such as textile machines

Commercial: luggage, hand tools, computer housings, ladders

Electronic applications Electronic applications include electronic packaging, hard drive arms, cell phone and portable media device housings. Magnesium alloys are being used instead of plastics due to their light weight, strength and durability. They also are relatively better for heat dissipation and protection against electromagnetic and radio frequency interference [5].

Medical applications Portable medical equipment and wheelchairs that require light material make good use of magnesium alloys. Also, cardiovascular stents and orthopaedic devices are potential applications of some magnesium alloys due to magnesium’s biocompatibility and bioabsorbability [4].

These metal casting processes both offer a wide range of benefits to the manufacturer, which can make it difficult to choose one over the other without detailed knowledge of their qualities.

Casting is a widely used method of producing metal products, especially those that are complex. Because molten materials readily form the shape of the container into which they are poured, casting fairly complex shapes is almost as easy as producing simple shapes.
The place where metal is cast is called a foundry. The most important cast metal is cast iron, which is made by remelting pig iron in special furnaces called cupolas.

Die casting is a fast, cost-effective manufacturing process for producing high-volume, reticulated, close-tolerance metal parts. It has the benefit of improved quality and repeatability and is often less expensive than other processes.

The die casting process is the injection of a molten metal alloy into a steel mold (or tool) under high pressure, where the alloy solidifies rapidly (from a few milliseconds to seconds) to form a net shape part, which is then automatically extracted.

Die casting tools typically produce any number of components ranging from hundreds of thousands to millions before needing to be replaced.

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