Development of Magnesium-Aluminum Alloy Die-Casting Parts and Drone Components

Magnesium-aluminum alloys, known for their excellent physical properties, are poised to play a significant role in the future of drones. The development of drones is moving towards lightweight designs, extended endurance, long-range control, interference resistance, and high-load capabilities—all areas where magnesium alloys can excel.

At present, industrial design and high technology are advancing rapidly. The future of drones will focus on lightweight, long-endurance, remote-controllable, interference-resistant, and high-load drones, which are ideal applications for magnesium alloys.

During World War II, the United States extensively used magnesium alloys, while Japan and Germany invested heavily in research and development before the war. Research funding worldwide was primarily directed towards military and aerospace applications, significantly enhancing the endurance and strength of military equipment.

Magnesium-Aluminum Alloys and Aerospace Applications

New magnesium-based materials are an ideal choice for future aircraft due to their light weight, which can significantly increase the range of these vehicles. They exhibit excellent castability, ease of machining, and can be formed into profiles for use as structural components in next-generation aircraft.

Properties of Magnesium Alloys

In the context of producing large quantities of identical parts, magnesium alloy high-pressure die-casting is notably superior to aluminum alloy high-pressure die-casting. This advantage arises because the solubility of iron in magnesium is lower, which significantly extends the lifespan of tools and castings. Additionally, the mold-filling time for magnesium alloy die-casting is reduced by approximately 30% due to its lower density—magnesium alloy is about 50% lighter than aluminum alloy, a significant benefit especially in the aerospace industry.

Apart from AZ91 or AM50/60 (e.g., DieMag633 or MRI230D), there are also cost-effective new die-casting alloys that exhibit very good specific strength at both room and high temperatures. For magnesium-based ductile alloys, choices are limited, with AZ31 being a typical representative. However, new Mg-Zn-Ca-based alloys are being developed, showing improved formability.

Nevertheless, magnesium alloys are susceptible to environmental effects, which can be mitigated with appropriate coatings. New anti-corrosion concepts for classic drones are currently under development and may need to adapt to construction constraints or depend on the vehicle's exposure conditions.

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