Development of Energy Efficient Integrated Die Casting Process for Large Thin-Walled Magnesium Applications

This project will develop an integrated super-vacuum die casting process using a new magnesium alloy to achieve a 50% energy savings compared to the multi-piece, multi-step, stamping and joining process currently used to manufacture car doors.  By substituting magnesium for steel inner panels, car doors could weigh 60% less, resulting in significant fuel economy improvements and carbon emission savings.