Mehdi Farrokhnejad, Jp Weiler, Jilong Zhang, Mingzhi Mao, Long Chen, Chen Liu, Zongyu Li
• Summary of the development of the design, manufacturing and validation of the largest magnesium alloy liftgate produced to date. • Principles and best practices utilized in thin-walled tool design. • CFD software analysis completed for optimized design and validation of process. • Liftgate inner castings were successfully die-cast at steady-state rate. Mass production of large thin-walled castings such as lift gates may introduce additional challenges compared with a typical casting in terms of tool design and casting process design. Proper die thermal management yields a high production rate and optimal quality parts as well as improved die life. The geometry of parts, physical properties of alloys, feeding system design and process parameters all have their own influence on the overall success of part production. In this paper, some of the major challenges and recommendations to consider during the tool and casting process design for FAW Lift Gate, a large thin-walled casting, are highlighted.