Manchester 24th 2008

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1 Magnesium Die Casting In Automotive Applications New trends and innovations Meridian Technologies Manchester 24th

2 Meridian s Global Presence 2

3 MERIDIAN IN THE WORLD 5 manufacturing plants 7 Business development offices 1400 Employees metric tons Mg 61 die cast cells (from 800t up to 3200t) Internal assembly and machining capability Turnover 2004 : 265 Millions 3

4 Major Magnesium Based Auto Products 4

5 Meridian key Products Instrument Panel Over 2,5 Millions per year Front End Carrier Over 0,9 Millions per year 4 Wheel drive transfer case Over 2 Millions per year Steering columns brackets Over 3 Millions per year Seats structure Over 0,4 Millions per year 5

6 Trends 6

7 Changes on the market - Cr Free corrosion resistant solutions (coated parts) => FEC - Low creep alloys with ductility, and good castability Engine Craddle (AE44) - Higher corrosion resistance of AE44 No coating on Engine Craddle - Higher Al cost Powertrain (Oil pans, brackets) 7

8 Front End structure Weight saving (50%) Stiffness (torsion) Fit and finish Air flow Corrosion (cosmetic) Relaxation/joints (100 C) Crash 8

9 Corrosion - General corrosion => No issues (no coatings on parts, ex: gear boxes) => High purity alloys => if cosmetic => coating 9

10 Corrosion - General corrosion => No issues (no coatings on parts, ex: gear boxes) => High purity alloys => if cosmetic => coating - Galvanic corrosion => Needs to be addressed 10

11 Corrosion Galvanic (structural) => Drain and insulate 11

12 Drainage Poor Better Design for corrosion Best Steel Drainage Mag Aluminium spacers 5000 series aluminum spacer Dissimilar metal mating part Drain holes greater then 10mm Ø 12 Magnesium part Lip added to aluminum insulator to break bridging

13 Joining with steel bolts Steel Coating Zn/Ni + Xylan Aluminium 5000 Series black anodised Washers 10 mm Coated AM 60 B Magnesium Plaque

14 Coating? No cosmetic requirement No cosmetic requirement No cosmetic requirement 14 Cosmetic requirement

15 Coating? Cosmetic requirement No cosmetic requirement Cosmetic requirement 15

16 FEC development Production Physical validation Development

17 Engine Cradle Engine Cradle -Temperature (150 C) - Crash requirements Low creep alloys - No corrosion pre-treatment 17

18 HISTORY: Project Started as a USCAR Project (United States Council for Automotive Research). Low creep alloys evaluated in terms of: - Castability (thin/thick walls vs. AZ91) - Properties (static, fatigue, creep, corrosion) Involved General Motors. Ford and Daimler Chrysler Development vehicle: The 2006 high performance variant of the General Motors Corvette known as the Z06 18

19 19

20 Alloy drivers: - Temperature (125 C) - Crash AE44 A%: 9-10 % ; YS: 125 MPa ; UTS: 230 MPa Base: A356 LPDC vacuum 13% elongation Design drivers: - Stiffness - Fatigue - Load & Strength Engine cradle Drivers 20

21 Future opportunities? 21

22 RheoDiecasting Clamping unit Inlet Twin-screw extruder T/C T/C Die High speed injection unit Professor Z Fan (Fan) BCAST (Brunel Centre for Advanced Solidification Technology) Brunel University 22 UK

23 The conventional HPDC process Hydraulic clamp Shot sleeve Piston Die 23

24 Rheo-diecasting (RDC) process Clamping unit Twin-screw extruder Inlet T/C T/C Die High speed injection unit Rheo-diecasting = Slurry maker + HPDC 24

25 Microstructure of rheo-diecast AZ91D parts 25

26 Property comparison with other processes (AZ91D) Thixo-c RDC UTS (MPa) HPDC Thixo-m Elongation (%) 26

27 Microstructure of rheo-diecast AZ91D alloy (Well dispersed fine oxide particles) 27

28 Summary Fine and uniform microstructure throughout the parts Improved mechanical properties Higher integrity (<<1% porosity) thus heat treatable Verify welding Thin / Thick walls capability? Tighter dimensional control Longer die life 28

29 To be tested and characterized at Meridian Including component tests in

30 Conclusions New trends and innovation: - Front end carriers - Engine cradles - Powertrain applications - Corrosion solutions - Low creep alloys for crash components - Development of fixing - RheoDiecasting potential 30

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