This study investigates the influence of RE elements on the room- and high-temperature properties of magnesium alloys. The effects of RE type, addition level, and multi-element alloying strategies were systematically analyzed to clarify the underlying strengthening mechanisms and processing pathways for optimizing Mg–RE alloys. RE elements enhance the mechanical and thermal properties of Mg alloys through crystal structure modification, formation of thermally stable dispersed phases, precipitation strengthening, and solid-solution strengthening. Compared with conventional alloying elements, RE additions offer distinct advantages in strengthening efficiency and overall performance. To fully exploit these benefits, new research paradigms that integrate machine learning and other advanced techniques are required, enabling the intelligent design of multicomponent alloy systems tailored to specific application requirements.

In order to effectively reduce energy consumption and increase range mile, new energy vehicles represented by Tesla have greatly aroused the application of integrated magnesium (Mg) alloy die casting technology in automobiles. Previously, the application of Mg alloys in automobiles, especially in automotive cockpit components, is quite extensive, while it has almost disappeared for a period of time due to its relatively high cost, causing a certain degree of information loss in the application technology of Mg alloy parts in automobiles. The rapid development of automotive technology has led to a higher requirement for the automotive components compared with those traditional one. Therefore, whatever the components themselves, or the Mg alloy materials and die casting process have to face an increasing challenge, needing to be upgraded. In addition, owing to its high integration characteristics, the application of Mg alloy die casting technology in large-sized and thin-walled automotive parts has inherent advantages and needs to be expanded urgently. Indeed, it necessitates exploring advance Mg alloys and new product structures and optimizing die casting processes. This article summarizes and analyzes the development status of thin-walled and large-sized die casting Mg alloy parts in passenger car cockpit and corresponding material selection methods, die casting processes as well as mold design techniques. Furthermore, this work will aid researchers in establishing a comprehensive understanding of the manufacture of thin-walled and large-sized die casting Mg alloy parts in automobile cockpit. It will also assist them in developing new Mg alloys with improved comprehensive performance and new processes to meet the high requirements for die casting automotive components.

The present study concentrates on the role and underlying mechanisms of in situ crystallization (employed for nanocrystal formation) in influencing the solidification microstructure and properties of aluminum alloys. By systematically analyzing the effects on α-Al refinement, silicon phase modification, and secondary phase control, as well as exploring the impact on room-temperature mechanical properties, high-temperature deformation behavior, and fatigue performance, this work reveals the potential physical mechanisms of improving mechanical properties by providing nucleation sites and inhibiting grain growth, such as fine-grain strengthening and dispersion strengthening. Moreover, stabilization of the second phase optimizes high-temperature deformation behavior, and a reduction in stress concentration improves fatigue performance. Compared with traditional microstructure control methods, in situ crystallization can achieve deeper grain refinement from micron to nanometer scale, ensuring high uniformity of grain distribution and showing good compatibility with existing processes. By defining the regulation of in situ crystallization on the microstructure and properties of aluminum alloy, the existing research provides a feasible material solution for high stress, high temperature, and high reliability. Its core significance lies in breaking through the performance bottlenecks of traditional modification technology, such as unstable refining effect, element segregation, and so on. The co-promotion of “strength–plasticity–stability” of aluminum alloys and the consideration of process compatibility and cost controllability lay a theoretical and technical foundation for the industrialization of high-performance aluminum alloys.