New Aussie casting technology wows the world

Three South Australian companies and the CSIRO have collaborated on a new means of forming magnesium alloy parts.

The new method, known as 'T-Mag', relies on gravity for the molten alloy to fill dies, avoiding the turbulence and consequent potential for porous casting, oxidation and other defects inherent in current high-pressure or vacuum methods.

By using a magnesium alloy in lieu of aluminium alloy, the T-Mag process results in parts claimed to be "two-thirds" lighter, ensuring cars are more fuel efficient and can attain an improved power-to-weight ratio.

That claim comes from the CSIRO's business development manager, Sam Tartaglia, who also says "The technology is being assessed by a group of major North American car makers. If successful, this validation will open the door to key markets. It's a fast-track entry into the market."

T-Mag is both simpler and more cost-effective than conventional magnesium alloy casting methods -- and places it in production cost striking range of current aluminium alloy and steel casting technology.

CSIRO and its partners (Alloy Technologies International, SAGE Automation, and FLOTEK) have already presented the T-Mag concept at the GIFA exhibition for the World Foundry Congress in Dusseldorf, Germany, back in June. The response from visitors was positive.

Technically, the T-Mag concept is simple and cheap -- a 3.5kg part requires just 3.7kg of raw alloy for production. Conventional processes would require at least 6kg of material. Raw material purchasing costs are thus reduced and the process also leads to better quality products without flaws, so there's less production-related wastage.

New production techniques such as this take years to implement, but engine blocks, wheels, suspension components can all be cast using this technique -- saving fuel and cost in the longer term.

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