IIT Madras devises new magnesium casting process for automobile, aerospace sectors

NEW DELHI: The Indian Institute of Technology (IIT) Madras has developed a new casting process for manufacturing magnesium. The process enables the creation of strong, lightweight and corrosion-resistant magnesium castings suitable for automobiles, aerospace and many other sectors. JEE Main 2025 Live

The process was developed by the Innovative Materials Processing and Characterization Research Group (IMPCRG) and Centre of Applied Magnesium Research under the supervision of Sushanta Kumar Panigrahi, head, manufacturing engineering section, department of mechanical engineering, IIT Madras, the press release read.

IIT Madras researchers have also been conferred the ‘International Magnesium Award for Innovative Process’ for 2024, the institute said. IIT Madras researchers are reportedly the first team from India to win this award.

Panigrahi said: “Unlike traditional casting methods, the ‘Strain Integrated Gas Infusion (SIGI) Process’ uses advanced techniques to create a more uniform and refined structure during casting, eliminating the need for additional treatments. This means the materials developed by SIGI process are stronger, more durable, and resistant to wear and corrosion. By combining efficiency with innovation, the process sets a new standard for manufacturing high-performance magnesium alloy castings.”

“The global shift toward reducing carbon emissions has prompted industries like automotive and aerospace to explore lightweight materials to enhance energy efficiency. Magnesium alloys, which are two-thirds lighter than aluminium and one-quarter the weight of steel, present a promising solution. Magnesium-cast components account for 80% of all applications of magnesium alloys, making their development critical for modern industries,” Vidya Tiwari, co-investor and research scholar, IIT Madras said.

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The SIGI process enhances the quality of magnesium alloy casting by refining its internal structure, obtaining non-dendritic grain structure with homogeneous alloy distribution, enhancing durability, and reducing both production time and manufacturing costs, the institute said.

IIT Madras: Benefits of SIGI process

The following are the benefits of the SIGI process as listed down by IIT Madras:

• Produces lightweight magnesium castings with improved strength, ductility and corrosion resistance.

• Boosts the production process and saves time, energy.

• Reduces manufacturing costs by eliminating the need for extra treatments.

• Supports sustainable development by enabling lighter vehicles that consume less fuel, lowering carbon emissions.

• Opens opportunities for industries to use magnesium alloys in a wide range of products, from automotive to aerospace sectors.

The institute further said that the research team at IIT Madras is now focusing on adapting this technology to other lightweight materials, including magnesium composites and aluminum-based alloys and composites, to broaden its industrial applicability.

This innovative casting process also holds great potential for fabricating composites with enhanced process efficiency, it added.