Outstanding Achievement: Magnesium Strut Tower Brace
Excerpt from the Modern Casting May 2020 article.
This year's American Foundry Society named 2 foundry castings with their top honors as well as 8 others for outstanding achievement. One of those companies achieved outstanding achievement for their unique cold chamber high-pressure die-cast magnesium strut tower brace.
Magnesium strut tower brace
Meridian Lightweight Technologies Inc. (Strathroy, Ontario, Canada)/Ford Motor Co. (Dearborn, Michigan)
Material: AE44 magnesium alloy
Process: Cold chamber high-pressure die-casting
Weight: 3.6 kg
Dimensions: 1075mm x 432mm x 137mm
Application: Automotive. 2020 Ford Mustang Shelby GT500 strut tower brace
Customer: Ford Motor Co.
This magnesium strut tower brace, a collaboration between Ford and Meridian Lightweight Technologies, is the first usage of AE44 magnesium die casting alloy for a visual application in the automotive industry. The magnesium casting is converted from a steel stamping and aluminum extrusion. It replaces two main structural components from the previous generation design to accomplish a weight reduction of nearly 50 percent.
The design of the strut-tower brace was optimized for die casting technology and specifically for magnesium die casting, allowing for a complex shape with the front surface moved 95mm rearward from the previous generation to visually highlight the intercooled supercharger manifold, while meeting all stiffness and durability requirements.