Design and Development of a Lightweight Seat Frame Using Magnesium Extrusions and Stampings

This paper describes the method and technology in which a combination of extruded and stamped magnesium components were used to develop a lightweight seat frame for use in automotive and/or aircraft industries. A current production steel frame was used as a base model for packaging comparison. A prototype sample was made based on simple design practices which, when tested, resulted in fatigue failure. A non-linear Finite Element Analysis was conducted which suggested some minor changes. Additional samples were than made and tested. The seat's performance data from tests conducted and a computer model from the Finite Element Analysis is submitted. An economic and manufacturing feasibility study was conducted to investigate the potential of such a system for high volume production. The results suggest that positive benefits will be obtained in the area of increased payloads and more efficient gasoline consumption by using a magnesium seat frame compare to an existing steel or plastic seat frame.