As reported by YZWeekly, FAW Group has developed a seat frame made of magnesium alloy using a semi-solid die casting process and has successfully completed its assembly. The component was developed as part of the “Hongqi R&D New Vision” initiative and has already passed initial functional tests. Strength, durability and vehicle tests will follow in the next phase. The development marks another milestone in the application of magnesium alloys for lightweight automotive design.
 
Magnesium alloys are gaining increasing importance in the automotive industry due to their low density, high specific strength and excellent vibration damping properties, which enable significant weight reductions. As a result, they are already being used in various vehicle segments to meet the growing demand for lightweight construction and CO₂ reduction.
 
For the new seat frame, the Hongqi development team optimized material, process and structural design. A dedicated magnesium alloy slurry was developed and process parameters were improved using virtual simulations, enhancing both mechanical properties and overall component quality. At the same time, the structural design was significantly simplified: instead of the original 19 individual parts, the seat frame now consists of four magnesium alloy components while maintaining the functionality of an eight-way seat adjustment system. This reduces assembly complexity and improves production efficiency. Compared with a conventional steel plate design, the weight of the assembly was reduced by 1.35 kg, equivalent to about 26%.
 
The seat frame is based on Hongqi’s modular seat frame platform and is compatible with various production and development models. In addition, the design remains largely compatible with existing steel solutions, facilitating the transition to the new technology while minimizing tooling investment – an important prerequisite for future mass production.
 
The development is supported by Baowu Magnesium Industry, which operates a fully integrated industrial value chain ranging from dolomite mining and primary magnesium smelting to magnesium alloy processing and recycling. The company has already developed several automotive components made of magnesium alloys, including seat frames, instrument panel cross-car beams, center console frames and battery module end plates. Some of these components are already being produced in series.
 
Die casting technologies – including high-vacuum die casting as well as semi-solid casting and injection processes – play a key role in this field. Continuous advances in alloy modification and process optimization are expanding the application range of magnesium alloys, particularly in lightweight, high-quality and precision manufacturing.
 
Source: Foundry-Planet. Image source: yzweekly and Baowu Magnesium Industry
 
FAW Foundry & Forging will exhibit at Asia's largest specialized die-casting and non-ferrous exhibition—CHINA DIECASTING & CHINA NONFERROUS 2026 (Shanghai New International Expo Center, Halls N1-N5) from July 15-17, 2026, at Booth N4A27 (TOP Casting Producers Area). Under the theme "Twin Engines: Al & Mg, A Lightweight Future," the expo is expected to span 52,000 square meters, attract over 600 exhibitors, and welcome 28,000 professional visitors. Colleagues from around the world are warmly invited to visit and exchange insights.
 
The global die casting industry is undergoing several major transformations: the scaling and industrialization of large megacasting, breakthroughs in rheocasting technologies, and the expanding potential of die casting beyond new energy vehicles - into fields such as Two-Wheelers (Emerging Trend: Replacing Aluminum with Magnesium), humanoid robot, energy storage, photovoltaics, and aerospace. As a barometer of the Asian market, the event will showcase technological advancements, product applications, and integrated solutions across these three key tracks.

Tags:   CHINA DIECASTING , CHINA NONFERROUS