In August 2006, Magnesium.com reviewed the potential for magnesium parts and components in automobile manufacturing and personal electronic devices. As 2007 unfolds, more and more consumer products are coming off the production lines with magnesium components.
In a 1999 feature article in Automotive Design and Production, Ford Research and Vehicle Technology Weight Engineering Manager, Tom Sweder noted the importance of car companies to develop lighter vehicles and component parts. This was not necessarily for the benefit of the consumer or car design or even the intrinsic value of the specialty metal parts; it was for automotive manufacturers to avoid paying penalties in CAFE. At the time CAFÉ, the Corporate Average Fuel Efficiency standards, penalties were $5.00 per car not meeting the corporate average of 27.5 miles per gallon for cars and 20.7 miles per gallon for light trucks. The penalty for failing to meet CAFE standards recently increased from $5.00 to $5.50 per tenth of a mile per gallon for each tenth under the target value times the total volume of those vehicles manufactured for a given model year.
In the late 1990′s sport-utility vehicles and trucks were popular consumer choices as they are today. Manufacturers developed some parts to lighten the load but mostly took a loss on the smaller cars to offset the gas consumption of the larger, more popular vehicles. A remedy to this problem was to increase power-train regulations or develop lighter vehicles on a system wide basis. More research and development went into aluminum parts and components for automotive production. There were some impressive developments with aluminum hoods and frames, and designing extruded components instead of stampings. Many manufacturers at the time were not familiar with or equipped to work with aluminum and eventually had either to learn the process or turn to other industries.
Magnesium.com has noted that many companies jumped right over the aluminum process to magnesium. In 2000, Ford had the opportunity to start working with magnesium seat frames, but due to lack of research and safety guidelines on magnesium chose aluminum instead. Industry wide the lack of research and standardized development seems to hold back car manufacturers from fully employing magnesium as a first choice in parts and components in today’s vehicles.
While wheels and engine parts are usually thought of as the mainstay of magnesium components, consumers also have the chance to get the latest computer technology with magnesium components. Mark Lisnyansky, CEO of Magnesium.com says, “Today’s consumers are concerned about fuel consumption and conservation, but they also demand top of the line accessories in and on their cars. What magnesium parts and components have done for the 3C (cameras, computers, cell-phones) products can now be applied to audio-video components in the automotive industry.” Mr. Lisnyansky also notes that, “While companies are developing dashboard frames, engine valves, tire holders and the like, custom wheels, computers, GPS display, cell phone, mp3, satellite radio, dvd players and screens are all, well almost necessities in today’s car.”
While many of these products are aftermarket installations by those who want to personalize their cars, many are factory installed. PC Magazine recently listed the top ten technologically ready cars. They are loaded with the latest audio, video, and computer technology available. Magnesium, considered an ideal metal for personal electronic devices, would surely be used in automotive design to meet the demands for the numerous personal electronic devices wanted in today’s car spaces. Engineers at SMW Engineering, a division of Magnesium.com state that, “The damping capacity, electromagnetic shielding and heat dissipation features make magnesium a preferred component in production and installing the audio, video and computer components with magnesium provide many plusses to automotive manufacturing.”
PC Magazine ranked the Infiniti M45, Honda Civic Hybrid, Toyota Prius, Mercedes Benz S550, BMW3 Series, Acura RL, Audi A6 4.2, Cadillac STS, Buick Terraza, and the Acura TL as the most technologically advanced cars on the market.
All of the cars have some variation of high-tech digital electronic components, computer or video display, sound systems, and adaptive technology, very few boasted substantial magnesium parts, and some only the paint color was labeled magnesium.
The Infiniti and Cadillac STS both have a magnesium cross-bar. The BMW3 runs on the new N52 magnesium/aluminum composite constructed 3.0L in-line six-cylinder engine. The Acura RL Strong uses lightweight magnesium for the front seat frames and engine valve covers.
Clearly, this is an area where magnesium parts and components can find a niche market. The car of future, according to the editors at PC Magazine would combine hydrogen or hybrid engines, LED lighting, high-voltage capacitor’s, advanced transmissions and airless tires, all areas where magnesium can be a strong leader in parts and component development.
Meeting CAFE regulations and being fuel-efficient are important concerns for consumers and manufacturers, but lifestyle influences can also push magnesium to the forefront in automotive development. According to Rides Magazine, “It’s not uncommon to see readers putting $10,000 and up into their cars. Wheels and tires are traditionally the first customization, followed by mobile entertainment, (audio, video, Play-stations and TV’s).” The time has come to develop this market for magnesium.