The researchers have used a technology similar to Tesla’s ‘gigacasting.'
The scientists used high-pressure casting to create the two parts using a technology similar to Tesla’s “gigacasting” process. This high-pressure “mega casting” leads to smoother surfaces, stable dimensions, and the ability to mold in a single casting and has been responsible for speeding up Tesla’s production in its Shanghai and Berlin factories, seeing the production cycle shortened from 1-2 hours to 3-5 minutes.
The researchers further noted that they had overcome any challenges to creating large magnesium alloy castings through structural design, raw material purification, casting process optimization, and other means. “Despite magnesium alloys’ slightly higher material cost compared to aluminum, the faster production speed and ability to produce more parts from the same amount of material makes the overall cost per part comparable,” Jiang said.
Carmakers everywhere are switching to more advanced casting processes for car bodies. Mercedes, Volvo, Volkswagen, and Toyota have announced plans to use mega casting, and Chinese carmakers, including Nio and Xpeng, are doing the same. Experts now say the trial casting could promote the large-scale use of magnesium alloys in large complex structures.
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