Recently, through independent R&D and collaborative efforts, FAW's R&D Headquarters has successfully developed the high-performance magnesium alloy housing HDU35 e-drive system. The assembly has been completed and is poised to enter bench testing and vehicle road testing phases. This achievement marks a key technological breakthrough for Hongqi in the lightweight application of magnesium alloys for core powertrain components.

Lightweighting is a critical path for new energy vehicles to enhance driving range and optimize energy efficiency. However, the application of magnesium alloys in core wet-area and high-temperature components such as e-drive housings has long been constrained by two major technical bottlenecks: corrosion and high-temperature creep. To address this, the Advanced Materials Research Group of the National Key Laboratory of High-end Vehicle Integration and Control at the R&D Headquarters focused on the pain points of magnesium alloy e-drive housing application. They conducted coordinated research tackling key areas including improving material corrosion and creep resistance, optimizing anti-galvanic corrosion connection processes, and iterating product structure and manufacturing techniques. Using the Hongqi HDU35 hybrid e-drive system as the application platform, the project team steadily advanced technology development and prototype trial production, ultimately succeeding in completing housing trial production and system assembly. Compared to the traditional aluminum alloy solution, this magnesium alloy housing achieves a weight reduction of 10 kg per set, signifying substantial progress in the related technological efforts.

The R&D Headquarters established a collaborative system with units including the E-Drive Development Department of FAW Qixin Power (Changchun) Technology Co., Ltd. and FAW Foundry Co., Ltd. From breakthroughs in core technologies like material modification, connection processes, and anti-corrosion treatment, to product design, simulation analysis, and process optimization, and further to die-casting debugging and trial production resource support, units involved in material R&D, product design, trial production, performance testing, and manufacturing implementation worked towards the same goal. This enabled a rapid leap from technical concept to finished trial product. This e-drive system will concurrently be installed in Hongqi vehicles under development for road testing, aiming to break down the cycle barriers from technology reserve to vehicle-scale application and fully promote the process towards mass production.

Magnesium alloy is currently the metal structural material with the lowest density in industrial applications. It boasts core advantages such as high specific strength and stiffness, excellent vibration damping, noise reduction, and electromagnetic shielding properties, ease of die-casting forming, and 100% recyclability. Among these, die-casting is one of the primary industrialized application methods for magnesium alloys. Its application fields continue to expand with advancements in material modification technologies (towards corrosion resistance, high-temperature resistance, high strength-toughness) and die-casting process upgrades like high-vacuum die-casting, semi-solid die-casting. The focus remains on application scenarios emphasizing lightweighting, high added value, and precision manufacturing, which aligns well with the high-quality development needs of the die-casting industry.

The successful assembly of Hongqi's high-performance magnesium alloy e-drive system not only breaks through the technical barriers for magnesium alloy application in wet-area and high-temperature powertrain components but also explores a practical technological pathway for the scaled application of magnesium alloys in core vehicle components.

China FAW Group Co., Ltd., formerly known as First Automobile Works, has established five major production bases in Northeast, North, East, South, and Southwest China, forming a global R&D layout. Its portfolio includes owned brands like Hongqi, Jiefang, and Besturn, as well as joint venture brands such as Volkswagen, Audi, Jetta, and Toyota, creating a comprehensive automotive product matrix and mature industrial ecosystem for all series and scenarios.

Source: Hongqi R&D New Horizon | Article translated from Diecasting Weekly.

Organized by the Foundry Institution of the Chinese Mechanical Engineering Society (FICMES), the CHINA DIECASTING & CHINA NONFERROUS Expo 2026 will be held from July 15 to 17, 2026, at the Shanghai New International Expo Centre (Halls N1–N4). As Asia's largest specialized exhibition for die casting and nonferrous foundry, this edition, under the theme "Twin Engines: Al & Mg, A Lightweight Future," is expected to span 49,200 square meters, feature over 600 exhibitors, and welcome 28,000 professional visitors. The exhibition will continue to focus on the global die-casting and nonferrous casting industry, showcasing cutting-edge solutions and technologies across the entire chain—from upstream raw materials, molds, and equipment supply to downstream application terminals. Industry professionals are cordially invited to visit and exchange insights.