Recent advances on magnesium alloys for automotive cabin components: Materials, applications, and challenges

Against the backdrop of the rapid advancement of new energy vehicles (NEVs) and in response to the significant demand for extended driving range, the utilization of magnesium (Mg) alloy lightweighting technology to reduce energy consumption has been revisited. The enclosed or semi-enclosed environment of vehicle cabins offers an intrinsic advantage for Mg alloy parts as it obviates the need for extreme corrosion resistance demanded by exposed exterior parts while leveraging the alloy's superior castability to meet the demands for integrated molding of complex structural components within cabins. However, apart from its high material cost, several technical challenges associated with Mg alloy components impede their widespread adoption in automotive cabin parts. For instance, inadequate material properties, limited application experience, constrained forming technologies, unresolved issues related to joining technologies between Mg alloys and dissimilar materials, as well as interfacial corrosion issues, have made automobile manufacturers exercise extreme caution when applying Mg alloys. A comprehensive understanding of Mg alloy properties for automotive cabins, its application history and current status, as well as key technical challenges during application, is crucial for overcoming obstacles and promoting wider adoption of Mg alloys in automotive cabins. Therefore, this article reviews the progress and applications of Mg alloys commonly used in automotive cabins. from the perspectives of materials, component applications, manufacturing processes, and existing challenges, with the expectation that the relevant information can provide references for the development of advanced high-performance aviation Mg alloys in the future.