Barriers to construction of a car made of magnesium alloys:
Designing a lighter engine and car frame is the talk of the automobile industry. However, the car that is built of this stronger and lighter metal has yet to surface. Sure, magnesium has been used to create tire rims for decades. The magnesium block engine is also being manufactured. The problems with using the metal alloy to completely replace steel and/or aluminum have problems that will require industry-wide cooperation before such a car materializes.
3 Things Standing in the Way of the Magnesium Alloy Car:
Cost of Materials Electrician Certification Online
Magnesium is a metal that is easily mined, but costly to refine into form needed to manufacture an automobile. Magnesium must be extracted using very high heat, which is also necessary for the casting process. Parts that are Steps To Start A Small Business not cast can be cold formed, but excessive pressure is required. These processes use very high amounts of energy (to run the facility and equipment), making them cost prohibitive to factories and supply makers at-large.
New processes are being created to take away much of the costs. The Thixomolding process used to form magnesium alloy sheets is one such process. It is cheaper than traditional processes without sacrificing the integrity of the magnesium sheet being produced.
Materials Availability
The problem of having magnesium available for manufacturing is actually being debated in the 2011 session of Congress. With a sole company in the U.S. that produces magnesium from salt mines, and tariffs placed on all magnesium imports, the issue is quickly gathering steam. The costs and shipping time make magnesium unavailable for mass production outside of the few parts using the metal currently. If production companies return to the U.S. and/or the tariffs on imports are reduced, this may change.
Manufacturing Redesign
Auto parts and manufacturing machinery is designed for steel forming, casting, and sheeting. Magnesium has a different process that would require a refitting of the factory to accommodate. The costs of time lost, new machinery and facility modifications are prohibitive for the industry right now. There is also the gap in production caused by the change to magnesium alloy metal from steel, therefore, companies could lose a few anxious customers.
These barriers to the wider use of magnesium in automobile production are being studied now to find a solution. The auto industry is known to “gnaw” on an idea for a while before producing a solution, just look at the electric engine. The magnesium alloy car will not be forgotten in the meantime.

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