Strong, Stainless, Thixomolded Magnesium Alloys for Zero Emission Automotive Applications

Electric vehicles have cost, range and performance limitations. Lightweighting the structural components of electric vehicles lowers energy consumption (kWh/mile), reducing the size, mass and cost of the battery pack needed. Magnesium, which is similar in cost and strength to aluminium, but a third lighter, is the best structural material to achieve significant lightweighting. Lightweighting is also relevant for robotics, aerospace and defence applications.

Thixotropic high-pressure die-casting (thixomolding) is an emerging method for manufacturing structural automotive components from magnesium. It produces higher quality castings and a refined globular microstructure. Preliminary tests show improved mechanical properties and corrosion resistance - but this is poorly understood and there has been limited alloy development for thixomolding.

This project will:

1) Characterise thixomolded components produced by industrial partner TPI Technology, to correlate the microstructure, mechanical and corrosion properties of commercial Mg alloys (AM60 and AZ91), providing understanding of the relationships between material processing and performance.

2) Develop new alloys specifically optimised for thixomolding, combining computational metallurgy and machine learning techniques with high-throughput experimental synthesis and characterisation, to develop optimised magnesium alloys with improved cast-ability, mechanical properties and corrosion resistance.

You will work with industrial partners Jaguar Land Rover, TPI Technology, Bruker and Magrathea Metals to maximise industrial impact of the work. This project will accelerate the adoption of thixomolded magnesium alloy components as a lightweight, affordable, environmentally sustainable alternative to current aluminium components for automotive applications.

Video on thixomolding: https://www.youtube.com/watch?v=9QRJQW5GdGk