This study is related to the development of lightweight automotive materials that were carried out to develop eco-friendly vehicles worldwide. High-strength aluminum alloy is used as one of the significant lightweight materials in the field of transportation machinery, and it is used as a lightweight material in various areas, including automobiles. The A356 alloy used in this study is an excellent aluminum alloy material that has widely used as a high strength aluminum alloy material in various forming methods. In this study, to examine the characteristics of the two alloys in which Mn and Sr elements were added to the A356 alloy and the A356 alloy, both alloys were manufactured by metal mold casting, which is a gravity casting method. The obtained specimens were heat-treated under the same conditions. In this study have investigated of the microstructure analysis, thermal analysis, crystal phase analysis, and mechanical property evaluation were performed to confirm how the added Mn and Sr elements influenced the microstructure, precipitate formation, and mechanical properties.

Aluminum High Vacuum Die-casting process has become more prevalent in automotive manufacturing industry which require high productive rate, weldable process and heat treatment process. However, high pressure die castings usually contain gas porosity due mainly to the entrapment of air or gas in the die during the high speed injection of the molten metal into the die cavity. Vacuum block system with disk spring was developed and vacuum chanel was optimized with numerical flow analysis. The porosity of die castings was analyzed by X-ray CT, and the effect of porosity on the mechanical properties was analyzed by hardness and tensile test. Tensile strength was improved 49.5% for 50mbar high vacuum die-casting process compare then 300mbar. And then, Surface property was analyzed with plunger velocity and fast shot set point.

The investigation on the lightweight of automobiles has been underway in commercial vehicles as well as passenger cars due to global warming and strengthening of European emission standards. In this study, the V-arm were developed for lightweight parts using aluminum alloy instead of steel with high pressure die casting processing. This study has focused on lightweight adaptive concept design. Several models of V-arm were designed and analyzed for the fluidity and solidification. V-arm was produced with ADC12 by high pressure die-casting process. The mechanical properties of developed V-arm were measured; such as tensile strength, elongation, shear strength, and durability. The possibility of mass production with the light weight aluminum V-arm substitute from the steel. The weight was reduced about 38% from 16kg to 9.98kg. The productivity was improved with decreasing the process from 8 to 5 by All-in-0ne process using high pressure die-casting.

Magnesium alloy is becoming known for the lightest material in the metallic materials. Recently the automotive industry has a variety application to the light weight parts replacement. This study focuses on the mechanical property improving through a tiny amount’s CNT addition into the magnesium alloy as AM60. The CNT material is an arduous combination of the metallic materials. Therefore this study is concentrating on the contact force growth for the CNT material. Consequently, the made CNT is produced by the CVD process using the magnesium catalyst. The CNT material has dispersive with mechanical process into the molten AM60 alloy. The mechanical experiment result that hardness is 18% increasing and tensile strength is 13% increasing, better than the raw AM60 alloy on this investigation.