AICE Expert Insights | Magnesium and Aluminum Alloys: The Next Big Trend in Die Casting Industry

Advantages of Magnesium and Aluminum Die Casting / AICE 2025 Advantages of Magnesium Die Casting 1. Significant Weight Reduction: The density of magnesium alloys is about two-thirds that of aluminum alloys and one-quarter that of steel. Under the same strength requirements, magnesium alloy components can be made lighter and thinner than plastic parts. If the front and rear longitudinal beams of a NEV are changed from aluminum to magnesium, the weight can be reduced from 190 kg to 130 kg. 2. Contribution to Fuel Efficiency and Emission Reduction: For every 10% reduction in vehicle weight, fuel efficiency can improve by more than 5%; for every 100 kg reduction in weight, fuel consumption per 100 km can decrease by about 0.7 liters. In the NEV sector, the weight reduction advantage of magnesium alloys can reserve space for increased driving range. 3. Excellent Performance: Magnesium alloys have strong shock absorption, good casting properties, high automation production capability, long mold life, and stable dimensions. Additionally, magnesium alloy materials are recyclable without affecting their performance, meeting the requirements for energy-saving and low-carbon production. 4. Huge Market Potential: According to China's "Energy Saving and New Energy Vehicle Technology Roadmap," by 2030, the average magnesium alloy usage per vehicle in China will reach 45 kg, while the current average usage in domestic vehicles is less than 3 kg. Guidelines issued by the MIIT and other departments also encourage the high-quality development of the casting and forging industries. Advantages of Aluminum Die Casting 1. Lightweight and High Strength: Aluminum alloys have a low density and high strength, offering an excellent strength-to-weight ratio, making them suitable for components that require both lightness and strength. In automotive manufacturing, the lightweight characteristics of aluminum die castings help improve fuel efficiency, acceleration, and suspension system response. 2. Good Casting Properties: Aluminum alloys have good thermal conductivity, electrical conductivity, and machinability, with small linear shrinkage and excellent filling properties, making them suitable for the high-precision manufacture of complex-shaped components. Aluminum die casting processes can quickly produce complex structural parts, suitable for mass production. 3. Corrosion Resistance and Durability: Aluminum alloys have good corrosion resistance, maintaining stable performance in harsh environments, making them suitable for use in the automotive and aerospace industries. 4. Economic and Sustainable: The raw material cost of aluminum alloys is relatively low, and they have a high recycling rate, further reducing material costs. The production process of aluminum die castings is relatively environmentally friendly, meeting the requirements for sustainable development. 5. Surface Quality and Post-Processing Advantages: Aluminum die castings have a high surface finish, reducing the need for subsequent processing and painting. Their good dimensional accuracy and consistency improve assembly quality and production efficiency. Alloy materials are among the best choices for human utilization of metals, and magnesium and aluminum alloys are top performers in this category. Their unique physical and mechanical properties make them indispensable in various fields. At the [Die Casting Industry Development Forum] held on April 16, 2025, at the AICE Aluminum Industry Expo, many industry experts will share their insights on the replacement path of magnesium and aluminum die casting. 2 Guest Introduction / AICE 2025 A member of the Ningbo Municipal Committee of the Chinese People's Political Consultative Conference, senior economist, and senior engineer, he is a veteran expert in the mold and die casting industry. He currently serves as the rotating chairman of the Mold Branch of the China Foundry Association; director of the Ningbo Mold Industry Cluster Promotion Center; executive vice president and secretary-general of the Ningbo Mold Industry Association; executive vice president and secretary-general of the Ningbo Machine Tool Equipment Association; chairman of Ningbo Tianzheng Mould Co., Ltd.; and chairman of Zhongmo Cloud (Ningbo) Technology Co., Ltd. His main work involves the planning and promotion of the development of the mold and die casting industries, as well as the empowerment of related industries through upstream and downstream industrial chain platforms. He has participated in the planning, development, and acceptance of multiple mold and die casting industrial parks in several cities across China. Challenges in the Replacement Path Insufficient Awareness: Some OEMs lack a deep understanding of the performance and application scenarios of magnesium alloys, leading to inadequate recognition of the benefits of lightweighting. Lack of Standards: There is a partial absence of standards for magnesium alloy components in China, which cannot fully meet the needs of sellers and buyers. Lagging R&D: China's high-performance magnesium alloy material industry lags behind in R&D, with key process technologies significantly trailing those of foreign countries. The development of high-end core materials is challenging, with slow performance improvements and insufficient capacity. High Costs: The R&D costs for magnesium alloy products are relatively high, which to some extent restricts their large-scale application. Opportunities and Trends in the Replacement Path Driven by NEV Demand: With the rapid development of NEVs, the demand for lightweight solutions is becoming increasingly urgent. As a "second solution" to replace aluminum alloys, magnesium alloys have broad application prospects. Boosted by Integrated Die Casting Technology: The maturation of ultra-large integrated die casting technology makes it possible to apply magnesium alloys to large automotive components. For example, Tianzheng Mould has achieved a 90-second production cycle for a magnesium alloy instrument panel bracket, significantly improving production efficiency. Technological Breakthroughs by Enterprises: Companies like Tianzheng Mould have made significant achievements in magnesium alloy die casting, such as developing the world's first magnesium alloy subframe die casting mold and continuously exploring higher-tonnage ultra-large intelligent die casting units. For more in-depth analysis, please attend the [Die Casting Industry Development Forum] at the AICE Aluminum Industry Expo on April 16, 2025, where industry experts will share their insights on-site! 3 Forum Introduction / AICE 2025 The AICE 2025 SMM (20th) Aluminum Industry Conference and Exhibition, focusing on the entire aluminum industry chain from ore smelting to metal processing and end-use consumption, will open at the Suzhou International Expo Center from April 16-18, 2025. As one of the most important forums of AICE 2025, the Die Casting Industry Development Forum on April 16, 2025, will focus on key topics such as the integration of NEV chassis, semi-solid aluminum die casting vs. magnesium, large integrated die casting structural components, high-pressure integrated die casting auto bodies, the future of China's die casting industry, aluminum trends, and the processes for integrated casting in electric drive systems, bringing an unparalleled event to the aluminum industry in the spring of 2025. 4 Forum Agenda / AICE 2025