Thixomolding is a method of molding semi-solid magnesium alloy pellets using equipment and processing methods similar to injection molding. Its commercial growth has been driven by its technical advantages, including enhanced precision, environmental cleanliness, and the ability to produce complex 3D shapes with high yields and minimal waste.

The hands-on experience provided during an Eisenman Materials Camp for students is a compelling way to excite young people to consider a STEM career. The volunteer-lead curriculum pairs a weeklong failure analysis project with many hands-on heat treating, metal casting, and materials characterization experiments. This article provides background about the Eisenman camp as well as the other student camps organized by the ASM Materials Education Foundation and discusses their benefits and long-term impact.

Thixoforming is a hybrid technology used to manufacture net shape components from a variety of alloys ranging from low melting temperature aluminum and magnesium to steel and Co-base alloys.

Aluminum components with refined microstructures produced by high pressure die casting enable manufacturers to gain energy savings via shorter production cycles—if casting and tempering parameters are optimized. This article reports on research results indicating it is possible to increase hardness of hypereutectic Al-Si alloys by optimizing the water quenching rate and duration of room temperature hold, and producing castings with finer microstructures.

This article addresses work to develop core technology for high pressure die casting in order to enable high volume and low-cost manufacturing of lightweight automotive components with complex hollow structural shapes. Although experimental verification of the concept using a part with simplified geometry looks promising, the technique requires further testing using commercial components with internal cavities of complex geometry.

Production techniques based on net shape forming from the liquid or semisolid state offer advantages in terms of manufacturing simplicity, cost, and energy consumption compared with current complex solid state forming processes. Engineering molten alloys to change their solidification process improves part integrity and alloy microstructure, leading to better component performance.

Thixomolding is an environmentally clean and safe commercial process for semi-solid injection molding of magnesium alloys. The process is similar to plastic injection molding but with higher temperature and faster shot velocity. This article reviews advantages and applications of the process and future outlook for it.

Understanding both the origin and procedures for removing inclusions in magnesium alloys results in castings with enhanced mechanical and corrosion properties. This article provides an overview of typical inclusions found in magnesium and its alloys, various techniques used to determine inclusion content, and methods employed to reduce inclusions and their influence on properties.

Aluminum-silicon (Al-Si) alloys have good castability in combination with high corrosion resistance, thermal conductivity, and specific strength, making them a strong candidate for many automotive applications. This article describes the processes used in the production of die-cast AlSi9Mg engine brackets for Volvo trucks, the effects of solution treatment temperature on Si particle size, and the benefits of Mg additions on yield strength and heat treatability.