Targeting High Impact R&D for Automotive Magnesium Alloys

Reducing vehicle weight improves the fuel efficiency, driving dynamics, and performance of vehicles ranging from traditional internal combustion engine (ICE) powered to battery electric vehicles (BEVs), fuel cell vehicles (FCVs), and the full range of hybrids [1]. However, along with tremendous opportunities, introduction of novel lightweight materials and architectures presents numerous engineering and commercial challenges. For the case of magnesium (Mg) the weight reduction potential, which exceeds 50% for some components, is offset by manufacturing, mechanical property, corrosion, and material cost hurdles, among others. While the vision of an all-Mg vehicle is laudable in its ambition, a more practical reality features Mg playing an important role in a multi-material vehicle architecture. In order to pursue the most promising and relevant Mg research and development, we need to assess several important questions: for which parts (or kinds of parts) is Mg best suited? What are the predominant engineering challenges preventing use of Mg for these parts? Where do we, as a materials science and engineering community, start in pursuing solutions to these challenges?