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Development of a Thin-Wall Magnesium Automotive Door Inner Panel
- J.T. Carter - General Motors LLC, USA ,
- J.C. O’Kane - General Motors LLC, USA ,
- S.A. Resch - General Motors LLC, USA ,
- A.K. Sachdev - General Motors LLC, USA ,
- Gerry Gang Wang - Meridian Lightweight Technologies, Canada ,
- K. MacKenzie - Meridian Lightweight Technologies, Canada ,
- C. Sweet - Meridian Lightweight Technologies, Canada
ISSN: 1946-3979, e-ISSN: 1946-3987
Published August 11, 2020 by SAE International in United States
Citation: Wang, G., MacKenzie, K., Sweet, C., Carter, J. et al., "Development of a Thin-Wall Magnesium Automotive Door Inner Panel," SAE Int. J. Mater. Manf. 13(3):199-208, 2020, https://doi.org/10.4271/05-13-03-0016.
Cast magnesium (Mg) door inner panels can provide a good combination of weight, functional, manufacturing, and economical requirements. However, several challenges exist including casting technology for thin-wall part design, multi-material incompatibility, and relatively low strength versus steel. A project was supported by the US Department of Energy to design and develop a lightweight frame-under-glass door having a thin-wall, full die-cast, Mg inner panel. This development project is the first of its kind within North America. The 2.0 mm Mg design, through casting process enablers, has satisfactorily met all stiffness and side-impact requirements, with significant mass reduction and part consolidation. In addition, a corrosion mitigation strategy has been established using industry-accepted galvanic isolation methods and coating technologies. The performance of the Mg design has been demonstrated through component and vehicle tests.
This article is an updated publication of a previously published International Mg Association (IMA) proceedings paper  (with agreement from the Association).