Evaluation of a Thixomolded Magnesium Alloy Component for Automotive Application

Thixomolding® is a semi-solid metal-molding process used to produce magnesium alloy components. The component quality is claimed to be high due to the low speed non-turbulent filling experienced in the thixomolding process. Parts of AM60 alloy were produced in a USAMP/DOE funded and directed project to demonstrate economic production of quality large thin wall, structural magnesium component using thixomolding. The selected application was the Ford F-150 shotgun; the structural connection between the A-pillar and the radiator support structure, and produced by G-Mag International. Test pieces were assessed through radiography and mechanical testing. The properties of the shot-gun casting were compared to those of experimental plate castings. Properties of the large casting were found to have a higher level of scatter compared to plate castings which can be attributed to the gas entrapment and oxide inclusions. The results are presented and discussed in this publication.