Magnesium alloy to help take a load off

Australian scientists have developed a technology called T-Mag which will allow cars to be much lighter without sacrificing strength. The technology is similar to that used in high-end digital cameras, the result is a permanent mould of magnesium alloy castings that have a high-integrity and lack porosity and other defects.

The weight difference is dramatic. T-Mag can be used to make a magnesium alloy engine block which weigh two-thirds of what an aluminum alloy block and less than a third of a cast iron block. The technology could also be used for wheels. Previous magnesium technology hasn’t been able to make safe and effective tires at a reasonable price.

Current high-pressure die casting uses six or seven kilograms of alloy to produce a 3.5 kg casting. Using T-Mag, only 3.7 kg of alloy is needed for the same 3.5 kg casting. Material that is not used in the process cannot be reheated and used again, so T-Mag cuts down dramatically on waste. It also saves money and energy by reducing melt costs.