What are the applications and challenges of magnesium in automotive structures?

Magnesium is the lightest structural metal (35% lighter than aluminum) used in instrument panel beams, steering column brackets, seat frames, and closures. Challenges include flammability during processing, galvanic corrosion requiring coatings and isolation, lower strength and ductility than aluminum, limited formability, and higher cost. Modern alloys and processing (die casting, sheet forming) address some limitations. Applications are growing, particularly in instrument panel structures and door inners where weight savings directly improve vehicle dynamics and efficiency.