GM Testing New Lightweight Magnesium Sheet Metal

The team at GM is currently testing a lightweight magnesium sheet metal in an attempt to increase usage of the extra-strong alternative to aluminum and steel.

The testing involves a thermal forming process and proprietary corrosion resistance treatment for the sheet metal. GM is hoping it will help increase use of low-mass components on vehicles throughout the world. They also plan to pursue licensing opportunities related to the new technology.

Employees from GM believe the increased use of the magnesium will help consumers save additional money at the pump. Magnesium weighs 33 percent less than aluminum and 60 percent less than titanium.

Up until recently, automakers have found it challenging to develop a reliably strong and non-corroding magnesium sheet panels using traditional methods of panel forming. With that said, GM has been turning up the heat on its magnesium (up to 450 degrees), providing the ability for it to be molded and formed into more exact shapes. Through the process, GM was able to test an inner deck lid panel which ended up having the ability to hold up to 77,000 robotic slams and 250-kilogram drops without issue.

While die-cast magnesium is commonly used in wide selection of parts ranging from engine cradles to steering wheels, GM is the first one to use thermal-formed magnesium sheet metal in structural applications.

GM Chief Technology officer and vice president of Global Research & Development, Jon Lauckner, said the use of magnesium is just another way GM is balancing new technologies which will benefit their customers all over the globe. He added the use of magnesium and aluminum is perhaps one of hte most effective ways to help improve both the fuel economy of a vehicle and its driving performance.

A number of automakers have went to great lengths in an attempt to develop a magnesium corrosion resistant. What do you think about your Buick or GMC having magnesium sheet metal?