Development of the 2006 Corvette Z06 Structural Cast Magnesium Crossmember

Since its very beginning in 1953, Corvette has been a pioneer in light weight material applications. The new 6^th generation corvette high performance Z06 model required aggressive weight savings to achieve its performance and fuel economy targets. In addition to aluminum body structure and some carbon fiber components, the decision to use a magnesium front crossmember was identified to help achieve the targets. An overview of the Structural Cast Magnesium Development (SCMD) project will be presented which will provide information on key project tasks. Project focus was to develop the science and technical expertise to manufacture and validate large structural magnesium castings, which provide a weight reduction potential of 35 percent with respect to aluminum. The die cast magnesium cradle is being produced from a Mg-Al-RE alloy, designated AE44, for high temperature creep and strength performance as well as casting ductility requirements. Extensive validation and post-test evaluations were performed on the Magnesium Crossmember.