For years, the automotive industry has promoted the use and need for steel in trucks, cars, and sport utility vehicles. So, the public began to ask for a more fuel efficient, less emitting and more economical vehicle. Newer, greener cars are answering this call. Amazingly, they have accomplished this without the use of the industry’s beloved steel. The trick is that consumers didn’t notice the material change.
The mysterious substitute for steel
Contrary to belief, magnesium alloys are much lighter than steel, cost less to manufacture, and make cars much more fuel efficient and “green.” Alloy is all of the following:
- A quarter of the weight of steel, but just as strong. In fact, magnesium is the lightest of all the metals used to build cars, buildings, and other structures like bridges.
- More resistant to impacts. Magnesium alloys absorb more energy from impact. Therefore, they are more resistant to teeth.
- The damping capacity or ability to reduce noise and vibration is also much higher than that of steel.
- Magnesium is less rigid and bends more easily than steel, making it easier to manufacture.
The alloy is not really new. It was discovered in 1755 by Joseph Black and isolated in 1808. The search for a more efficient and abundant material has led researchers to experiment with magnesium alloys instead of more traditional materials like steel that don’t perform as expected. The aforementioned factors have made the alloy a novelty in the automotive industry.
The faces of magnesium in cars
Some of the earliest automotive uses for magnesium were inside the car. Die-cast steering columns, engine blocks and chassis were just some of the uses for the alloy in automobiles. The vehicles were much lighter, used less gasoline, and had fewer emissions as a result. Eventually, the seat frames, dash panels, and the track that supported the sunroof were also cast from magnesium. Naturally, the next step was to bring the alloy to the exterior of the car.
Sheets of magnesium alloy made roof panels, hoods, oil pans, and other common automotive exterior items lighter, stronger, and more impact resistant. Expenses were a concern for the die casting process, but sheet is less expensive because it requires less compression force to create, allows for part consolidation, and simpler designs. Also, magnesium alloys have a very predictable shrinkage rate and less energy is required to manufacture the sheets.
Therefore, alloy is a step above steel, without sacrificing safety. One of the most common misconceptions is that cars made of magnesium alloy instead of steel are less safe. Now you know the opposite is true. Magnesium alloys may completely replace steel in the future.