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A series of comparative tests were conducted on two geometrically-identical automotive oil pans, one produced from A380 aluminum - pulled directly from its high-volume production line - and a second produced in a casting trial using DSM's MRI 153M creep-resistant magnesium alloy. While the theoretical differences in mechanical behavior of cast aluminum parts versus cast magnesium parts are relatively simple to determine, very few quantified, experimental comparisons exist. Where these comparisons do exist, they are often performed on simple shapes. Therefore, the objective of this project was to compare the stiffness, modal behavior, natural frequencies, and damping ratios of the two materials in a complex, functional geometry. Stiffness, natural frequencies, and flexural modes were determined using holographic laser interferometry and finite element analysis. Natural frequencies, modal behavior, and damping ratios were determined via hammer-impact excitations.

High pressure die casting (HPDC) is the dominant process for the production of magnesium components with complex configuration having typically thin to medium wall thickness. The growing use of die cast Mg alloys in the automotive industry, particularly for the production of drive-train components, has led to the development of creep resistant alloys, MRI153M and MRI230D, which were launched into the market several years ago. The present paper aims at exploring the effect of the HPDC process parameters on the porosity and, as a result, on the properties of the two MRI's developed alloys in comparison with common alloys AZ91D and AM50A that are usually considered as benchmark die casting alloys. The outcome of the research performed includes processing guidelines and recommendations, which allow obtaining high quality sound castings. These recommendations should be implemented in the course of design, optimization and production of high-performance components for various applications.