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Development of Integrated Die Casting Process for Large Thin-Wall Magnesium Applications Enabling Production of Lightweight Magnesium Parts for Near-Term Automotive Applications, April 2013

General Motors LLC - Warren, MI

An integrated super-vacuum die casting process uses a new magnesium alloy to potentially achieve a 50% energy savings compared to the multi-piece, multi-step, stamping and joining process currently used to manufacture car doors. By substituting magnesium for steel inner panels, car doors could weigh 60% less, resulting in serious fuel economy improvements and carbon emission savings.