Eco-sustainable lightweight automotive part manufacturing: GHGs-free die casting of brake leverage prototype made of AZ91D-1.5CaO magnesium alloy

Employing non-flammable AZ91D-1.5CaO Eco-Magnesium® (Eco-Mg) alloy in the European project CRAL provides the lowest carbon footprint for the magnesium cast process. Non-flammable magnesium AZ91D alloyed with Ca (in the form of CaO) was successfully processed by experimenting specific casting process window to melt the non-flammable magnesium alloy in a stationary furnace with no SF6 cover gas and then poured in the air into a vertical shortinjection displacement press machinery specifically developed in EU CRAL project. Brake leverage made of AZ91-1.5CaO Eco-Mg series alloy was successfully manufactured at Brembo Spa premise, as a real example of Mg cast component alternative to the current component made of forged aluminium alloy. As discussed in the experimental part, a preliminary computer-aided simulation test campaign reduced uncertainty in cast trials. The CRAL EU project with the realization of Mg-SF6 free cast part for brake systems has promoted the drastic reduction of Global Warming Potential (GWP) of the Mg cast process route. The Eco-Mg series is a feasible and affordable casting solution for introducing non-flammable Mg alloys in the automobile sector; today struggled for researching cost-driven lightweight components due to forthcoming CO2 emissions restrictions.