Idra Enters the Thixomolded Magnesium Game // But What is It?
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- เผยแพร่เมื่อ 14 พ.ค. 2024
- Idra Group, which pioneered the Gigacasting machines that Tesla uses for their massive underbody castings, is now working on giga scale machines for chip cast magnesium, which is also known as Thixomolded magnesium. The question is, what is that? Today I'll walk you through exactly what it is and how it compares to other casting technologies.
Video #1: • Unlocking Magnesium fo...
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Timeline
00:00 Introduction
01:04 Video Context
01:47 Aluminum Gigacasting vs Magnesium Thixomolding // What’s the Difference?
05:18 Rheocasting vs Thixomolding
08:21 Why did Idra Pursue Thixomolding instead of Rheocasting?
09:36 Thixomolded Magnesium vs Gigacast Magnesium
11:22 Thixomolding // Quality
12:51 Thixomolding // Speed
13:31 Thixomolding // Size
15:12 The Limiting Factor for Thixomolded Part Size
16:51 Why Not Thixomolded Aluminum?
19:17 Summary
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At the risk of sending you down a rabbit hole, I'll let you in on an open secret within the casting industry. "Porosity" itself is an incidental symptom of the underlying mechanism for low ductility, fatigue strength and reproducibility of castings. Magnesium and aluminum oxides are high-melting compounds with essentially zero solubility in the base metal, and only microseconds are required for a metal surface to oxidize on exposure to air. So when certain metals flow turbulently, the surfaces recontact and form some inflated bubbles that are visible as porosity, but also a lot more empty or nearly empty bubbles known as bifilms.
These are present from the entire melting history of any given piece of metal. The inside of the bifilm is weakly or negligibly bonded to itself in many (but not all) common alloy systems, so they are ready-made cracks or microcracks, waiting to be opened by stress or to corrode, or to open by combined stress and corrosion. This is mostly the origin of limited ductility or fatigue strength in structural metals.
The limited exposure of this phenomenon in open literature is not for lack of Professor John Campbell and his disciples, many of whom have their own foundries, telling anyone who cares to listen. Behind factory/foundry doors, it seems very likely that some know perfectly well about bifilms and use cheap effective workarounds to avoid or mitigate them in their products. See for example the common use of electroslag remelted steel in high end products like tank guns vs the allegedly superior VIM-VAR version.
Thixomolded products probably have a high bifilm content but of controllably small size. The bifilms originate from the magnesium chips, but they are most likely shredded by the auger and consequently kept to very small reproducible size. The viscosity of the thixomolded shot probably improves the part quality by means of producing laminar flow as you suggest, but the mechanism is to prevent the formation of large bifilms in the course of injection. This also reduces porosity, but most bifilms are not visible as porosity, especially in castings formed under high pressure.
😲🤯 I'm going to need to re-read this a few times. Thanks for the well written and insightful comment! 💯
@@thelimitingfactor You're welcome! Campbell's book, Complete Casting Handbook Metal Casting Processes, Metallurgy, Techniques and Design Second Edition is the place to find this explained at length and compared to the reality of casting various alloys.
Fascinating and well written. So would chipping in an oxygen-free environment solve this problem? Or chipped with some means of cathodic protection?
I've always read about this particular process with magnesium being called chip casting. When I think of thixocasting/molding, I think of starting with a metal that already has a globular microstructure before you melt it, with rheocasting being starting with molten metal and producing the globular structure as you cool it to get the semi-solid state. since you're clearly an expert, I wanted to ask if I have the terms straight since that's not how Jordan was using them in the video. also, all that stuff about casting and bifilms is really cool.
and just some more curiosity and spitballing as an aerospace engineer (just graduated from Purdue) with a minor in materials engineering. I'm curious about what you think as a knowledgeable materials professional.
As long as the metal is kept in an inert atmosphere or vacuum, I feel like laminar vs. turbulent flow shouldn't matter since there's no oxygen to react with, you just have what was there when you started.
My understanding of semisolid casting is that it reduces hot cracking and residual stresses. with a normal casting microstructure, you get interlocking snowflake-like grains that get stuck long before the melt is fully solidified, so you can end up with sealed pockets of molten metal that turn into porosity when the metal shrinks as it solidifies and introduce stresses that can cause hot cracking. that's not to mention the terrible columnar grain structure at the surface of the mold where it cools quickly. Since semi-solid metal has seed grains that are almost spherical (hence "globular") in the melt, they can slide past each other to relieve stresses and allow molten metal into voids until much later in the solidification process. The globular grains in the melt also produce the nice equiaxed microstructures you find in forged parts as the melt solidifies. Dramatically reducing hot cracking also allows you to cast alloys and shapes that would otherwise be impossible and the reduced shrinkage makes near net shape with less finish machining possible. near net shape is especially useful for complex geometries and/or narrow and deep cavities that are hard to machine.
I'm pretty sure the size limitations on semi-solid casting (at least outside of magnesium chip-casting) is that because the viscosity is so much higher you need much higher pressures than conventional casting to fill long and intricate flow paths before the melt solidifies. Those gigacastings seem to have flow paths that would struggle with semi-solid aluminum without a lot of extra injection pressure, though it is less of an issue than it could be since you don't need as much residual pressure at the end of the flow path. I think semi-solid magnesium might work better because its improved specific stiffness comes from lower density, so all the features are going to be significantly thicker with less pressure loss than an aluminum casting.
@@smit5983 Yes, but very hard to be sufficiently oxygen-free in a production environment if that is the only mitigation. Less oxygen helps (eg in high pressure die casting evacuating 99% of air from the die seems to really reduce the chances of worst defects) but the relevant level of "oxygen-free" is ~parts per trillion. Also some alloys have elements that strongly react with nitrogen too. Many ways to skin this cat with varying degrees of efficacy.
Idra is killing it right now.
Amen!
What about their parent co lk tech though? They have an in service 16,000 ton machine and developing a 20,000 ton one with neta in China inc setting up an actual casting demonstration center.
Afik Aluminum is at least as reactive as Magnesium. The difference is that Aluminum instantly forms an air-tight oxide layer when exposed to air. This oxide layer is so durable that it even makes molten aluminum look inert. This durable air tight aluminum oxide layer probably also makes Thixomolding much more difficult. Likely causing machine wear and brittle parts as it gets folded into the metal paste.
🎯 You're correct! I may have oversimplified in an effort to get the point across and keep it simple.
Yes. I was at v forge. It sucked
@@ryanbeard1119 Wow, what's it like to be over 260 years old?
@@AtlasReburdened are you talking about a reference to v forge?
Aye but I can put Al on a flame without it going up like a flare
Wow, learned a lot from this one. Thanks for sticking with it and doing what you do!
Glad to hear it! 🤩
Very nice explanation. It makes it clear why Tesla would go with molten Aluminum at this point in time.
Thank you for your time and effort you put into these videos. Very insightful.
This is one of your WOW vids. I literally called several of my friends & brother to tell them about this vid. I also recommend your vids to people at my local community college when they come out.
Well shit, that's a big compliment thanks! I'm glad the it proved to be useful/interesting!
@@thelimitingfactor hes totally right, i will do the same as he does!..... this video is just spectacular!
Magnesium has lower specific heat, less joules, calories, or whatever need to be pulled from the casting to reach removable solidification.
I am thinking of the potential savings in the tooling. With conventional HPDC there can be 5 sets of tooling produced. 1 production. 1 reserve. 3 in maintenance. If using magnesium the tooling is lasting 80% longer, then there is more time for maintenance. This in turn means less sets of tools are required. That is a mega cost saving.
Good point! That's something I'd have to look into
The Limiting Factor keeps on impressing
Thank You for this OUTSTANDING video !!! I need to do some reading on this process now .....
Merry Xmas, and thanks for your great research as usual.
Thanks and Merry Xmas to you too!
Well, today I learned. Thank you Jordan. : )
Fantastically informative video. Thank you for making it.
Thanks for the kind words!
Fascinating. Thanks Chiff
thanks for a well prepared and well delivered lesson !
🤜🤛🤠
Epic, as ever. Thanks.
Certainly a well made video! Nicely detailed and presented.
🙏🏼
One of the Best videos I ghave seen on youtube, Explains very clearly the magnesium forming process by two different methods.
🙌🏼🤠
Good to know Tesla's investments in Gigapresses won't go to waste should they decide to switch to Magnesium castings.
Thixomolding reminds me of gas station slushy machines but bigger
😂💯
And, yes, if you then freeze your slushy, you'll find it has excellent mechanical/structural propertes
Thank you!
very interesting video... has me wondering about thixomolding injection for Roll to roll Magnesium and Lithium systems. Great work.
The advantage you don't mention is the structural boundaries inside the material , the similarity to forging or even wrought iron structure is fascinating, the fibrous or complex nature means far more ductility and resistance to cracking , just examine cast iron to Wrought Iron differences , they are working at the same mixing level as forging without the working input , excellent bit of lateral thinking
That's a really good point!
It's fair to say this was oversimplified
Good explanation Jordan, thanks. Looks like there are a few technical problems yet to be solved (including cost and availability of Mg), but when they are solved, this will be an advancement in technology.
Great summary!
Terrific video, thanks.
You're most welcome!
Very Well Done.
🙏
you're doing God's work my friend
12:32 comparing yield strength of different materials on its own isn't useful in this case, because it's a geometric property. lower yield strength means that a magnesium part will fail earlier than an aluminium part of the *exact same shape*.
since Mg's density is lower, you will in many cases be able to change the shape of the part (e.g. increase wall thickness) to compensate for loss of strength and still end up with some weight savings.
directly comparing yield strength makes sense when comparing materials with similar density, like different Mg alloys or different steel grades.
I'm not sure what you mean, of course material properties matter. So do geometry and part quality.
Excluding any of them doesn't make sense because they all matter.
I don't think I said at any point that I was comparing any one of these factors to the exclusion of the others.
@@thelimitingfactor You state in the video that it's important for Mg castings to have low porosity "because [Mg] tends to be a weaker [...] metal than Al". On the screen you show a yield strength comparison with Mg being very slightly worse. I interpreted this as 'Mg castings need to be higher quality than Al castings to compete with Al because Mg has lower yield strength' (although you never made that statement). I wrote the comment because I disagree with this interpretation.
As above, it's a multi-variate problem.
All these things matter.
If material properties didn't matter, then we could make castings out of Jell-O and have them be commercially viable.
@@thelimitingfactor I think @wotthel3ll's point was that specific strength might have been a more useful comparison than strength by itself. specific stiffness might also be a useful comparison since it's often a more important metric in structural design where buckling tends to be the weakest failure mode.
Ran the buehler prince machines in briggs and stratton casting aluminum. The Die pressure over 20 tons. Was a cool job.
As useful as this would be for automotive castings, I am particularly eager to see magnesium displacing aluminum in aviation. Every pound counts!
The history of Mg in aviation is not so successful. But with modern tech, it may be good. I have personally been flying with a magnesium engine and was discussing with my teacher in engineering how to make the airframe in magnesium back in 1974.
The Germans were using massive (for the time) magnesium forgings in airframes during WWII.
It's nothing new.
@@jimurrata6785
Yes, it’s not a _new_ idea, as indeed few are, but until recently there wasn’t much hope of it viably displacing aluminum in a modern context, for a variety of mundane, practical reasons.
It's called Elektron been used for 100 years in aviation en.wikipedia.org/wiki/Elektron_(alloy)
Why is magnesium useful for automotive?
As nearly always very well done Jordan.
The casting process reminded me of a long time ago when I had been working before and during studying at an aluminum casting company (having seen all three processes).
Re Video, maybe it was already answered:
22 miles/hour -> *88/55 -> 35.2km/h -> 9,77 -> 10 m/s. (SI is better).
Pricing Aluminium vs Magnesium based on volume - seems similar.
Can Magnesium be welded similar to Aluminum in case of repair?
Can Magnesium be welded on steel as Aluminum?
Good points/questions!
Cost will be covered in the next video
As for the welding - not sure. I may cover it depending on how many videos I do.
Can be welded but care with shield gas is needed
Thanks!
You're most welcome! Thanks for the support
From what i remember, the firewall in the Gen V SRT Viper is cast Magnesium.
You’re such a nerd.
I love it!
😂🤜🤛
It is such a marvel of a video! Just a small error (you mentioned it later correctly), SO2 is a quite toxic gas unlike SF6 which is inert to human body.
Nice video and presentation.
Right, there is a little to none fire hazard in a controlled production process. The chance for post production model3 magnesium to catch fire on road remains a concern. Not only the battery can be ignited but including the magnesium part as well.
Coverd in the first video
Sem palavras esse documentário
As a former firefighter I hope they only use magnesium castings in vehicles that have battery chemistry that is not capable of combustion.
All batteries are capable of combustion unfortunately...anything that stores that much energy can light up
I wonder how much larger casting machines can be used in other industries, e.g. planes, trains, boats, military applications... etc. Seems like large castings with light weight could be highly beneficial across much much more than just autos. Potentially cutting 30% weight with minimal compromise is a huge deal, and adding high production throughput to the equation with potentially lower failure rates would immensely advantageous.
🙌🏼
If you've heard of the Heavy Press Program (en.wikipedia.org/wiki/Heavy_Press_Program ), 50000 ton press forges made in the 1950'ies. Largely they were used for things like titanium bulkheads for military aircraft. Insanely expensive, but if cost is no objective go for it.
I'm sure the IDRA sales team is all over it, don't worry.
(magnesium as 3d print material )
I think the 04-07 F series had a magnesium casting that was really close to 10kg. It was a die casting, Used as a radiator support.
Argon is also an asphyxiant. All gases except oxygen and air are asphyxiants.
And ? Anything is dangerous even custard as you can drown in custard , takes some doing but you can ,
@@kwinterburn Just stating the fact. Jordan, at 6:50, insinuated that Argon had an advantage over Sulphur Hexafluoride and Sulphur Dioxide because those two are asphyxiant gases. I was pointing out that Argon is also an asphyxiant hazard, as are ALL shielding gases.
I'm not sure why people use the word insinuating, as if there's something devious going on. I said that the argon is contained, whereas the cover gas is sitting in open air. That is, despite both being asphixiants, the argon is extraordinarily low risk because it's contained.
Amazing video. These tech improvements are impressive. I'm wondering what will Tesla do with this? Clearly a 33% weight reduction for parts implies more range. Perhaps the 1st vehicle to benefit from this will be the smaller new generation platform? If gigacasting the entire vehicle with magnesium were possible, perhaps aluminum could be completely replaced in that vehicle? (I'm assuming it will be a smaller vehicle)
What about other vehicles? Model 3 and Y, Cybertruck, Semi? Perhaps some parts would be replaced by Magnesium castings?
How much weight could that save for those? The potential improvements range from seeming good enough to perhaps astounding engineering achievements!
It'll be a couple of years. Idra indicated 2025 and tesla is already tooling for the compact vehicle.
@@thelimitingfactor Interesting. Thank you! So, it seems we will see lots of improvements in Tesla vehicles by 2025, amazing!
@@thelimitingfactor In the US, avg occupancy 1.2, avg daily mileage under 40 afaik. I can see a magnesium micro car suitable for eg Europe and other dense cities around the world. US planning and zoning laws will change.
Thanks
Sure thing man! 🤠
MMC’s like carbon / magnesium are suitable for thixocasting……interesting times ahead. Love your work. Cheers.
Interesting! What does MMC stand for?
@@thelimitingfactorMetal-matrix composites. The metallic phase forms the matrix, while the reinforcing phase (whether whiskers, chopped fibers, filaments etc) is either carbon nanotubes or some other hard phase, typically a ceramic. MMCs have superior toughness (along with increased yield strength) compared to the base alloy. I do wonder if tool wear becomes a more significant issue though…
I wonder if it’s feasible to comold aluminum parts with magnesium, or the other way around.
The idea being you get the light weight of magnesium but a bit more rigidity from the Aluminum.
So you start with an aluminum part with lots of holes and such for lower weight, sort of a skeleton, then inject magnesium to co mold it, potentially with some heating of the original aluminum part to encourage molecular bonds/alloying where the two metals meet. Then you have a magnesium part with embedded aluminum for strength.
You could then plate it with another metal if the magnesium oxides are undesirable on the surface of the part.
Generally, the way this is solved is by alloying.
Most aluminum alloys contain magnesium and most magnesium alloys contain aluminum
Another reason for the conversion to magnesium alloys is they can be produced as a bulk byproduct in lithium extraction or salt water desalination or salt production so very low co2 production mostly bulk solar evaporation in salt estuaries gravity and the sun do the work so low on labour and machinery cost to boot.
Thanks great video. After a quick check, it seems that magnesium has 60% the density of aluminium, not 33% as claimed in the video.
1/3rd less thhat equates to 66%
🎯
what are the cost of aluminium and magnesium : just curiosity
Idra is going to make a mint when all the other automakers want to move their manufacturing (of god knows how many model variants) to gigacastings.
i hope they do. they seem to have earned it. I am totally blown away by how they make the carmakers look like complete fools. specially the european ones close to where i live! :)
Looking at racing motorcycles from the 1970s and 1980s, which often used magnesium to save weight in wheels, engine cases, carburetors and assorted brackets, restoration is very difficult due to the much greater corrosion of magnesium compared to aluminum.
Unless there's an alloy of magnesium which is far more corrosion resistant than those used in the past, I don't really see the advantage of it's use unless these vehicles are intended to be disposable.
It's a series on magnesium and that was already covered
From the IDRA slide you show it's not quite clear if they plan to achieve the 20 kg shot weight using one or using two plastifier screws, but I guess it's with two.
That's because it wasn't a deep dive into Idra's technology, but rather explaining generally what it is and how it compares to other technology. Regardless, it's two - the slide says twinscrew boost.
@@thelimitingfactor So if they use two screws, that means they made far less progress on the shot weight per screw than the 20kg figure implies. According to wikipedia shot weight per screw is the main limiting factor in scaling thixomolding machines.
Sounds like a poor way to define limiting factor if they were able to double the shot weight in total - which is what matters.
They were able to do that by using a piston, which is an innovation.
Is it better to use fewer screws? - probably. But given these are the first thixo machines they've created, we're looking at version 1.0.
So, it's too early to make a judgement.
Wow my brain started hurting halfway through! To much information for me, brilliant but to much.😂😂
Great video. Magnesium can be drawn out of sea water as well as calcium and sodium and a few other metals by means of electrolysis . This process could make the Tesla hundreds of pounds lighter and increase it's range by maybe %8 or so. Hard to say. But an air plane made of magnesium and a better battery with solar assist would be a winner.
Amen! And thanks for watching! The video dropping tomorrow will get into this 😀
This makes me so proud to live in Brescia even if....
No, wait, I actually live in Brescia!
😅
😁💯
I wonder: could an alloy of magnesium and aluminum split the difference in cost, corrosivity, and weight in a gigacasting?
Almost all aluminum alloys contain Mg and all magnesium alloys contain Al for that reason. They're complimentary
The trimmings can be shredded and sent right back into the hopper. No need to remelt and make ingots.
I'm getting magnesium pilled
Can a part be thixomoolded to a near net shape, and then forged? Wouldn't that be the best of both worlds? I have no idea what im talking about, just pondering.
They're two fundamentally different ways of shaping metal.
And the way you shape a metal affects its crystal structure.
So you can do one or the other.
Beyond that, using two processes would double the production costs because it requires double the equipment, etc
You need 50+ ton iron giant presses for same
As I understand it the best Magnesium Casting Alloys are not as strong as the best Aluminium Casting Alloys and so though Magnesium is considerably less dense than Aluminium you will need more of it in order to make a component of a given strength.
So, how does this play out ultimately in terms of the final weight of the component?
From memoery, it still ends up being lighter by like 20% rather than 33%.
But, that's for equivalent casting processes.
I've seen magnesium thixomolded parts weigh up to 41% less than the aluminum HPDC equivalent.
But, this is the wrong question anyways...
It's mainly about cost because Al and Mg have always been somewhat interchangeable for some use cases and Mg has been subtituted when the Mg price gets low enough.
I'll get more into cost in the next video.
Can these cast parts be repaired easily or are cars made with them a huge liability to insurance companies?
Certain parts of the casting are sacrificial.
So they can be replaced easily.
If it gets to the point where it hits the primary part of the casting then the vehicle would be totaled anyways.
Had to reflect, why not make a wheel that is this novel magnesium? Further reducing rotational mass and getting further efficiency?
Bingo! Going to cover that in the next video of the series. It would provide a 3-5% range boost while costing less, improving acceleration and handling.
Can high strength aluminium alloys like 7075 be diecast using thixomolding?
I don't know about that specific alloy, but I saw number of different alloys in the literature. It appread that anything that could be HPDC cast could be thixomolded, but I'd have to look into it
Thoughts on titanium injection molding? Seems like a metal with better inherent properties than magnesium.
The melting temperature is too high, it costs too much
This is fascinating! Brain food for me:)
My obsessions with electric cars, Elon, and the internet have taught me so much.
Thank you for adding (a lot) to my knowledge bank👍👍
Good job I checked that, I wrote knowlege:) I should have left it.
Glad you enjoyed it!
Ketchup is has thixotropic viscosity
It resists flow until it starts to flow
Bingo! Great example
They may be addressing the fire hazard while manufacturing but I'm not clear how they mitigate it once the part is installed in the vehicle? In the 70's "Mag" wheels on hot rods would burn so hot that they melted into pavement and they were so hard to put out that firefighters essentially just let them burn. Gigacast sized magnesium parts paired with batteries seems like a dangerous combination.
Watch the first video of the series
What's the stress-strain curve of HFS like? I'm betting on 1'690 MPa and 25% elongation.
No Clue! I've been wondering too though
Where do you find this information?
🤠 I just keep track of things on X, file them away, keep my eyes out, and then eventually the video comes together.
Along the way I often meet experts and when it comes time to do the video, I pick their brains to add a little bit of extra detail and accuracy
@@thelimitingfactor so cool. I often feel like mainstream media covers up all the interesting topics. Its really nice to know the possibilities if designing new stuff
is it weldable or repairable?
Actually, due to the low porosity, my understanding is that it is more weldable
Has the topic of putting so much magnesium next to large lithium batteries may be a really bad idea? No matter how rare the event may be it's been proven that it happens even at this early low adoption rate of EVs. Unlike a ICE vehical where the magnesium may or may not burn the batteries will definitely set off the alloy. This poses a risk to rebar reinforced structures, steel ships, and more. Plus isn't it bad to put water on burning magnesium but the only hope to slow a lithium battery fire is lots and lots of water?
That's why I already covered this in the first video, and why I referred to that video in this video.
Multiple injection points for the same mold?
Not sure what this means. There's one injection point but two screws, but this hand off the material to the injection piston
Yes, with our MAXImolding(R) Vertical Multiple Injectors mounted on the top platen of the downstroke press.
More than one point of entry-delivery of molten goo. @@thelimitingfactor Then the volume pushed in, per unit time, is doubled or whatever.
If the goo "joins" well at the junctions, then you can make larger, more elaborate castings.
Perhaps even run two whole presses side by side squeezing a single mold between them, with multiple injection points, to deliver molten goo. Route the vacuum to help draw the goo in strategically.
You got a snark filter for that?@@ashleys8209 LOL!
Never thought plastic molding and light metal molding would become seemingly so similar.
How is SF6 a greenhouse concern? It's more dense so it'll just sink into the dirt.
Google it.
Google it
@@thelimitingfactor Ok sir:
"How much worse is SF6 than CO2?
Protect the Environment - SF6 is the most potent greenhouse gas known. It is 23,500 times more effective at trapping infrared radiation than an equivalent amount of CO2 and stays in the atmosphere for 3,200 years."
Again, my point is not the refractive properties, or how potently it retains heat.
My point is that it will sink into the porous earth and be inert.
So how are these greenhouse properties a concern? Subterranean air does not contribute to the greenhouse effect.
Wow it weighs less than aluminum thats cool as hell
It seems like trying to control a metal slurry with temperature would be a requirement but not nearly sufficient.
As far as cover gas vs vacuum, really all of this would need to be done under metal evaporation type vacuums to be under full control.
Well presented but please note that sulphur dioxide is toxic (7.04 into the video).
Depends on how you define toxic.
I flashed information up on the screen so people could make their own decision.
Almost anything in large enough amounts will kill you.
It is an irritant at minimum, but lethal if that's all you're breathing.
lol i thought you meant the SC2 player, Idra
😂
This chanel should have 1M subs it is of BBC class, thanks!
🤜🤛 You're most welcome!
If Idra needs magnesium chips at a very good price, then they should contact me. My company produces a large amount of magnesium chips daily.
👍👍
How much more does Mg cost than Al in industrial quantities? I'm guessing that it will be significantly higher because of the much lower abundance of the metal.
Roughly 50%, but it varies wildly over time.
Ahhh what‘s the point? Is Tesla goin there or not? What‘ll be the ultimate benefit? I zoned out so quickly 😂 Edit: ok got it 2 3rd weight reduction.
Next video is the 'tech porn.' Either way, overall, this isn't the place to go if you're looking for that.
Magnesium castings would make tesla fires even more exciting.
🎇
Since when has SO2 been nontoxic?
Depends on how you define toxic. The dose makes the poison
Fascinating. I do wonder what the world of business marketing wank will do for hyperbole in a few years tho - they've already overused all of the most overblown words we have. 🔥🔥🔥"GIGAcasting" 😮 must be HUGE!!! *we can cast whole aircraft carrier hulls in one piece now?* Nah, we can make a whole Tesla cyber wheelbarrow in one go though 🤦♂️ *Giga* 😂😂😂
😁💯
18:43 what does Strip of Gates mean? Or maybe the correct question is, what’s a gate?
A gate is the port through which the molten metal enters the mold.
This ends up as a stem attached to the finished casting.
Jim explained it, but I'd add that you have to strip them off after the part is cast...it's important for casting the part, but then it's scrap
@@thelimitingfactor Ah! 'strip off' not strip of....
I was picturing something akin to pig iron with one main gate and a row of sprues.
BUY TESLA STOCK Now
Very good. A little repetitive.
start out being interested in Elon Musks endeavors
become fan and interested in Tesla
invest
learn more to improve investment thesis
understand technical details with their battery technology (core tech)
eventually watch videos on how Tesla's suppliers have potential for new tech haha
LOL! That's about right
Airplanes are made of aluminum alloys because aluminum alloys are twice as strong as magnesium alloys and only 55% more dense than the magnesium alloys.
Correct, but we're talking about cast alloys that contain no rare earths
We had magnesium transmission in our helicopters, if they caught fire they could not be put out with ant fire retardant. Not a great idea
Poor logic.
Vehicles are a different use case.
You'll burn alive in the car from things like plastic before the magnesium starts on fire.
As I said in this video, watch the last video.
@@thelimitingfactoron that question. Have the rules for plastics in cars changed in the not too distant past? Iirc there was a big push toward the end of last century to get materials in vehicles, houses, and other human vicinity applications to be made at least fire retardant. Now you seem to see vehicle fires (on video) where the internals seem to burn through very quickly, ie do not appear to be fire retardant at all. Have the regulations been relaxed for some reason, maybe eco reasons, or am I just imagining that vehicle interiors seem to burn better than they used to. Genuine question, thought you may have some insight.
Interesting video by the way, on a subject I was not familiar with.
flammibility is an issue with magnesium. re: battery fire ignition and resulting conditions after ignition.
As I said, covered in the last video.
20k requires 7K ton clamping force, so 6K ton giga presses are out of reach. Even with higher strength and other advancements we are still talking about at least 40kg MY front castings. ~14k ton clamping force? Such a machine wouldn't be cheap and may not be economically viable for M3/MY market segments even with less expenses on dies. So, looks like in coming couple of years it would be more useful as an electric motor casing or similar parts. But in this case it's just a couple of kilos weight reduction to the car. Not that revolutionary like body castings.
I have no clue what you're saying.
Thixo machines are injection pressure limited rather than clamping force limited
@@thelimitingfactor The slide at 20:33 says 3.500 t - 7.000 t clamping force. Also, the clamping force is what opposes the injection force when pushes the dies apart.
2011，For the first time, BMW has used aluminum-magnesium alloy materials in the new 3 Series mass-produced engines, which reduces the weight of the engine by 30% and reduces fuel consumption by 16% compared with aluminum materials. The top-of-the-range new 330i is equipped with a 6-cylinder engine. The output power is increased by 20 kW/27 HP compared with the previous generation, reaching 190 kW/258 HP. It can obtain a maximum torque of 300 Nm at 2500-4000 rpm. , the acceleration time from 0-100 kilometers is only 6.6 seconds, and the top speed is limited to 250 kilometers/hour.
Nice!
For a while, after the Great War Reloaded, lots of unemployed aircraft engineers created tiny cars made out of aircraft -style materials and that technology, cars that made perfect sense in the economic doldrum after the Second Unpleasantness.
Personal vehicles should return to that mindset - Smaller, Cheaper, Better! The German DMV goes incremental in the weight of the vehicle class, because it Definitely SHOULDN'T give driving licenses like candy to teens, to start driving Hummers & other overweight vehicles over 2 tons. Otherwise, as ruled by the Supreme court that "Money is free-speech", ANY teen with the money for it will go over to Any Dealer and purchase the biggest baddest vehicle he saw in movies or games, and promptly rearrange the landscape, and , with Some Luck, rearrange his & his adventure buddies' bodies into a Picasso "masterpiece", so's to render themselves inert & safe.
As it stands, the "law" distinguishes Not At All the weight of the vehicle when a nut goes to screw around with the metal monster bought on a whim by a guy or kid with fewer neurons than money in the bank.
So we want to put a battery that can fail and burn extremely hot under a metal framework that can burn out of control 😅. No thanks, I'll pass.
You'll get used to it, just like you take all the other hazards in your life for granted. Your phone is actually a bigger risk - unless you don't have a cell phone.
As long as we don't start to make armor or military vehicles out of it....
Fair call
Only a complete fool would use a magnesium structural casting to hold a battery that goes into thermal run away unless the purpose is to make the fire hotter and shortens the time that the debris can be put into a dumpster. No smart insurance company is going to insure such a collection of poor engineering choices.
The vehicle you're driving today probably has magnesium in it.
Your smart phone has a highly volatile lithium battery in it, and it's in contact with your skin for a large portion of the day.
That is, you're surrounded by these dangers constantly, but you've become acclimated.
As for the insurance part...
That's silly, they already ensure these vehicles and magnesium and batteries have been used in vehicles for years.
More won't make a difference.