IIT Madras researchers' casting process for magnesium to help aerospace & automobile manufacturing

Researchers at the Indian Institute of Technology Madras (IIT Madras) have developed an innovative casting process for manufacturing magnesium—a critical lightweight material for automobiles, aerospace parts, and medical devices. The breakthrough will aid in production of lighter vehicles that consume less fuel, reducing carbon emissions, the research claimed.

The research team explained that their patented process, known as the ‘Strain Integrated Gas Infusion (SIGI) Process,’ makes the production of strong, lightweight, and corrosion-resistant magnesium castings, which have several industrial applications.

“The research team is now focusing on adapting this technology to other lightweight materials, including magnesium composites and aluminium-based alloys and composites, to broaden its industrial applicability,” IIT Madras said adding that the new material holds great potential for fabricating composites with enhanced process efficiency.


The research was led by a team from the Innovative Materials Processing and Characterization Research Group (IMPCRG) and the Centre of Applied Magnesium Research.

Sushanta Kumar Panigrahi who headed the research from Manufacturing Engineering Section at the institute said, “Unlike traditional casting methods, the SIGI Process uses advanced techniques to create a more uniform and refined structure during casting, eliminating the need for additional treatments,” adding that this means the materials developed by this process are stronger, more durable, and resistant to wear and corrosion.
The researchers also highlighted the process's ability to cut down production timelines, reduce manufacturing costs, and enable new industrial use cases compared to aluminium alloys.
“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,” said co-inventor Vidya Tiwari.
The IIT Madras team became the first from India to win the prestigious ‘International Magnesium Award for Innovative Process of the Year-2024.’ The award, jointly conferred by the International Magnesium Society (IMS) and the Journal of Magnesium and Alloys (JMA), recognizes pioneering work in magnesium science and technology.