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Driving Changes For The Car Of The Future
The technology, T-Mag, enables super-light magnesium alloys to be cast into high-integrity, high-strength automotive components, such as mag wheels.
by Staff Writers
Canberra, Australia (SPX) Aug 10, 2007
Casting technology developed by the Light Metals Flagship has given the Australian automotive industry a technical boost in the move to make lighter, more fuel-efficient cars. The technology, T-Mag, enables super-light magnesium alloys to be cast into high-integrity, high-strength automotive components. Low production costs make T-Mag castings cost-competitive with aluminium and steel automotive components.
"With T-Mag you can make a magnesium alloy engine block that is two-thirds the weight of an aluminium alloy engine block," CSIRO business development manager Sam Tartaglia says.
"T-Mag is designed to be simple," CSIRO casting team leader Dr Thang Nguyen says. "The result is an improved power/weight ratio and increased fuel efficiency and performance, which are much sought-after by premium car makers.
"The technology is being assessed by a group of major North American car makers. If successful, this validation will open the door to key markets. It's a fast-track entry into the market."
T-Mag is being taken to market by a partnership between CSIRO and three South Australian companies, Alloy Technologies International, SAGE Automation, and FLOTEK. The partnership has attracted a $1.95 million grant under AusIndustry's Commercial Ready Program.
T-Mag excited commercial interest when it was exhibited at GIFA, the World Foundry Congress, held in June in Dusseldorf, Germany.
"T-Mag is designed to be simple," CSIRO casting team leader Dr Thang Nguyen says.
"We've integrated melting and casting operations in a single compact unit which uses gravity rather than high pressure or vacuum to make sure the die fills smoothly from the bottom. This minimises turbulence and formation of oxides in the casting."
The result is strong, lightweight castings which do not have flow lines or internal porosity; defects which have hampered uptake of magnesium alloy castings made using existing technology.
In addition, T-Mag provides large savings in recycling and energy costs by reducing the metal needed for casting. T-Mag needs only 3.7kg of alloy to cast a 3.5kg component, compared with the 6kg to 7kg required by conventional processes.
The Light Metals Flagship's portfolio of material and process technologies focuses on transforming light metals, such as aluminium and magnesium, into products. A number of Flagship technologies are relevant to the automotive industry.
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