Vacuum-sealed molding process for magnesium casting: Numerical simulations and design of experiments

Given the rapid projected growth of magnesium casting usage in the automotive parts marketplace, there is a critical need to develop casting technologies applicable for a wide variety of part shapes, sizes, and production rates. The application of magnesium components will allow reduction in vehicle weight, improvement of parts-consolidation and minimization of noise/vibration characteristics. Magnesium is considered the fastest-growing metal in cars. Many of the earliest applications are instrument panel components, valve covers, etc. These are produced by a reasonably mature die-casting technology. Many potential structural components for automobiles could be converted to magnesium if a high volume, cost effective manufacturing process were developed. In this paper we propose a modified vacuum-sealed molding process for magnesium casting. Some results of computer modeling and design of experimental research are presented.