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Materials Today: Proceedings 4 (2017) 6743–6749 www.materialstoday.com/proceedings

iMagCon2016

DEVELOPMENT AND PERFORMANCE VALIDATION OF

ENGINE OIL PUMP FOR PASSENGER CARS USING
MAGNESIUM ALLOY
R. Seetharamana *, B Lavanyaa, Nutan Niharikab, P Thyagarajanb
a
Product Engineering Development, Sundram Fasteners Ltd - Autolec Division, Chennai-77, India.
b
Advanced Engineering Department, Sundaram Clayton Limited, Chennai-77, India.

Abstract

The auto industry world over is being challenged by emission control and light weighting. Magnesium alloy has been used for a
wide variety of applications, mainly due to its low density and high strength – to - weight ratio. Exceptional damping capacity
and low inertia makes it suitable for parts undergoing frequent and sudden change in motion direction. An oil pump casting has
been developed with AZ91D Mg alloy and validated for the performance that is similar to that delivered by component presently
made from ADC12 Al. alloy. The castings are evaluated for properties like density, hardness, internal porosity, weight reduction
and tensile Strength. Machining parameters like flatness and surface finish are observed by changing the cutting speed, feed, and
cycle time during machining. Electrochemical impedance spectroscopy is carried out to evaluate corrosion resistance of the
castings. The current research focuses on light weighting of engine oil pump casting and its performance validation.

© 2017 Elsevier Ltd. All rights reserved.

Selection and Peer-review under responsibility of the Conference Committee Members of International Conference and Expo on
Magnesium (iMagCon2016).

Keywords: Magnesium alloy(AZ91D); Oil pump; Performance testing; validation.

* Corresponding author. Tel.:+ 0 9884314996; fax: +91-44-2627-2696.

E-mail address: Seetharaman.r@sfl.co.in

2214-7853© 2017 Elsevier Ltd. All rights reserved.

Selection andPeer-review under responsibility of the Conference Committee Members of International Conference and Expo on Magnesium
(iMagCon2016).
6744 R.Seetharaman / Materials Today: Proceedings 4 (2017) 6743–6749

1. Introduction

The density of Magnesium is two-third that of Aluminum possesses excellent mechanical and physical properties.
With the inherent advantages of the metal casting process, magnesium alloys yield cost-effective solutions.
Magnesium is the lightest of all structural metals, weighing 35% less than Aluminum and 78% less than steel.
Percentage of Magnesium used in automobiles has been traditionally low, with an average of about 4.8Kgs in
typical domestic model in European countries.

The most prevalent casting method for Magnesium is die-casting. In this process, complex, thin-walled parts are
produced at high production rates aided by the low-heat content per volume of molten metal. Both hot chamber and
cold chamber machines currently are used for Magnesium. For optimum performance, it is recommended that higher
shot speeds are used for Magnesium compared to Aluminum, especially for thin-walled parts. Die-casting process
variants (such as vacuum die casting) can produce components with lower porosity and better properties.

2. Casting process

Magnesium alloy castings can be produced by nearly all of the conventional casting methods, namely, sand,
permanent, and semi-permanent mold and shell, investment, and die-casting. . The choice of a casting method for a
particular part depends upon factors such as the configuration of the proposed design, the application, the properties
required, the total number of castings required, and the properties of the alloy.

In the die casting process, it can be cast up to four times faster than aluminum. Die life is considerably longer than
with the aluminum alloys, because much less welding onto the die surfaces takes place. When protected correctly,
particularly against galvanic effects, it behaves in a very satisfactory manner. Modern casting methods and the
application of protective coatings currently available ensure long life for well-designed components. Magnesium
alloy casting facilitates product design with thin walled structures and product weight can be even optimized to a
great extent by shape optimization.

2.1 Improved Die Life

Unlike molten Aluminum, molten Magnesium does not react with tool steels, resulting in longer die life and
increased productivity. Because of low erosion and reduced heat input, which reduce the propensity for thermal
fatigue (heat checking of the die), casting Magnesium can achieve three to four times the die life than that of
ADC12.

2.2 Process Parameters

The process parameters of the Oil Pump Body part produced in 840T machine: Locking Force (KN) - 7500

Injection Pressure (bar) – 600

Cavity Fill Time (ms) – 58

Slow Shot Velocity (m/s) – 0.5

Fast Shot Velocity (m/s) - 3

Biscuit Thickness (mm) - 25

Ingate Velocity (m/s) – 30.

 R.Seetharaman / Materials Today: Proceedings 4 (2017) 6743–6749 6745

2.3 Post casting processes

The castings are shot blasted and coated to achieve corrosion resistance. When protected correctly, particularly
against galvanic effects, it behaves in a very satisfactory manner. Modern casting methods and the application of
protective coatings currently available ensure long life for well-designed components.

2.4 Salt spray for coating:

No observation of white rust on the casting after 120 hours of salt spray on trivalent coating with 5% Nacl
concentration. Various coating processes, and the life of casting is given in Table 1.

Table 1. With Nacl concentration as 5%

Coating type Salt spray
life(hours)
Trivalent coating 96
Solvent cleaning + liquid painting 144
Epoxy polyester 360
Pure polyester 500

3. Experimental data

3.1 Machining:

Magnesium is the lightest structural metal and exhibits excellent machinability. Some of the advantages of
machining magnesium compared to other commonly used metals include:
• Low power required – approximately 55% of that required for Al.
• Fast machining – employing the use of high cutting speeds, large feed rates and greater depths of cut.
• Excellent surface finish – extremely fine & smooth surface achieved.
• Well broken chips – due to the free-cutting qualities of magnesium.
• Reduced tool wear – leading to increased tool life.

3.2 Tool Materials:

 Carbide tools are predominantly used for machining magnesium alloys

 Due to sharp edges of the tools flank build up is possible which can be minimised by using uncoated tools
 PCD tools are used only when the production rate is highly demanding

3.3 Tool Design:

• Good results are normally obtained when Magnesium alloys are machined with tools designed for
Aluminium
• Because of low resistance to cutting and relatively low heat capacity of Mg tools should have
 Smooth faces
 Sharp cutting edges
 Large relief angles
 Small Rake angles
 Few Blades (Milling tools)
6746 R.Seetharaman / Materials Today: Proceedings 4 (2017) 6743–6749

3.4 Cutting fluids for Magnesium Machining

Magnesium is frequently machined without a cutting fluid because of following reasons:

• The improved surface finish and increased tool life that cutting fluids provide for other metals can be minor
consideration for magnesium
• Magnesium dissipates heat quickly and this keeps machine surface cool
• Free machining nature of magnesium and its resistance to galling against steel allows magnesium
to be machined without a lubricant
However, during tapping, reaming and deep hole drilling operations coolants help flush away the chip.

3.5 Safety Procedures in Magnesium Machining

 Magnesium is generally safe and stable at temperatures up to its melting point unless it is present in a finely
divided form.
 During cutting, roughing and medium cuts will produce large chips, which are difficult to ignite However,
fine finishing cuts will produce fine chips which will result in a fire hazard.
 At any point during cutting, the tool or tool holder should not be allowed to idle and run on the work
because it would lead to the production of extremely fine chips and the frictional heat generated maybe
enough to cause ignition.
 When cutting is completed it is important to maintain the same safe practice and not allow the feed to stop
and the tool to dwell upon disengagement.
 The cutting tool must be kept sharp and the tool surfaces must be smooth or polished.

4. FEA Analysis

The FEA results on Magnesium alloy casting made on ADC-12, leaves a factor of safety 1.6 over 2, which
further can be optimized through designing the part using Optistruct by defining material to arrive optimum model
for Magnesium alloy.

5. Product validation

Oil pump made up of ADC-12 & AZ91D are tested for performance flow, Leak test, Endurance test. The results are
as below.

5.1 Performance Testing:

Oil pump is tested for flow at different RPM`s & at pressures.

Oil pump used: Spintex 12.
Temperature: Room temperature.
No change in product performance with AZ91D material.

5.1.1. Leak testing

Oil pump castings made out of both ADC12 and AZ91D are tested for leak DIP method. Casting set up is fully
immersed in Distilled water tank for 20 seconds. No leak observed in both castings up to 6 bar.
 R.Seetharaman / Materials Today: Proceedings 4 (2017) 6743–6749 6747

5.1.2. Endurance Testing:

500 hours of Endurance test is carried out on oil pump made out of Magnesium alloy – AZ91D (as shown in Fig.1).
The test results are in line with existing pump.

Test Conditions:

RPM: 4000

Pressure: 3 bar

Oil used: SAE 15W40

Temperature: 90° C

Fig.1. Oil pump testing explained in 5.1.2 endurance testing.

5.1.3 Radiographic Test:

Radio graphic images of castings are taken using GE make X cube machine (explained in Fig.2)

Test procedure standard:

ASME SEC V
Source to destination: 14``
Source: Ir 192

Fig.2. Porosity analysis in the castings with ADC12 & AZ91D

6748 R.Seetharaman / Materials Today: Proceedings 4 (2017) 6743–6749

5.1.4 PQ Curve

PQ Curve is visual representation of the relationship between flow & pressure. For the curve Maximum Flow rate is
the X-axis & Pressure is the Y-axis. PQ curve for the oil pump made with AZ91D material is (as shown in the Fig.3)

Fig.3. Performance curve plotted against the tested results of oil pump made with AZ91D

6. Limitations

The reasons for the limited use of Magnesium alloys is low creep & low corrosion resistance. Corrosion rates of
modern, high- grade Magnesium alloys are acceptable for interior applications; the automotive exterior
environments are extremely harsh for bare & even coated Mg parts. First, road salts and slurries can easily damage
conventional electro coat paints, creating sites for rapid electro chemical dissolution of Magnesium. The metal is
prone to serve galvanic attack when in contact with other metals. In automotive structural components road salts,
debris can accumulate around bolts and washers that mechanically affix magnesium parts, such areas tend to absorb
galvanic corrosion. Therefore cost –effective solutions for protecting Mg alloys from corrosion has become
paramount.

When Magnesium is in direct contact with other metals

One of the best ways to combat galvanic corrosion of Magnesium is to use isolation materials to prevent direct
contact between bare Magnesium and dissimilar metals. If a high torque load is required, such isolation materials
must be made of special metals or inorganic substances that minimize excessive deformation upon locating. In
particular the use of aluminum washers can significantly reduce corrosion.

Conclusions:

Magnesium alloy aluminum castings proved for oil pumps for leak testing, performance and endurance. However
Engine level validation needs to be carried out. It also improves machinability, but needs to be addressed for surface
protection, further galvanic corrosion on matting part.
 R.Seetharaman / Materials Today: Proceedings 4 (2017) 6743–6749 6749

References

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