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This paper provides an overview of the research efforts within the AUTO21 program on magnesium die-casting. The objective of the program is to better understand the mechanical properties of magnesium high pressure die-castings (HPDC) and to develop the capability to predict the local mechanical properties over a given component based on its shape, the design of the mold and the casting parameters used in its production. The paper highlights the research group's findings related to the microstructure and mechanical properties of a full-scale instrument panel beam casting and outlines the goals of the continuing research program.

Ford GT 2005 vehicle was designed for performance, timing, cost, and styling to preserve Ford GT40 vintage look. In this vehicle program, many advanced manufacturing processes and light materials were deployed including aluminum and magnesium. This paper briefly explains one unique design concept for a Ford GT instrument panel comprised of a structural magnesium cross-car beam and other components, i.e. radio box and console top, which is believed to be the industry's first structural I/P from vehicle crash load and path perspectives. The magnesium I/P design criteria include magnesium casting properties, cost, corrosion protection, crashworthiness assessments, noise vibration harshness performance, and durability. Magnesium die casting requirements include high pressure die cast process with low casting porosity and sound quality, casting dimensional stability, corrosion protection and coating strategy, joining and assembly constraints.