Squeeze Casting of Aluminum and Magnesium Alloys for Electric Vehicles

The rapid growth of electric vehicles (EVs) has intensified the demand for lightweight metallic components that offer high structural integrity, reliable thermal performance, and improved energy efficiency. Squeeze casting has emerged as a key manufacturing route for aluminum and magnesium alloys, combining the geometric flexibility of casting with the microstructural refinement achieved through pressure-assisted solidification. This mini critical review synthesizes current advances in squeeze casting of A356, 6xxx, and 7xxx series aluminum alloys, as well as AZ91, AM-series, and rare-earth-modified magnesium alloys. The process–microstructure–property relationships are examined with emphasis on dendrite refinement, porosity suppression, enhanced mechanical performance, and improved thermal characteristics. EV-specific applications—including motor housings, battery trays, structural subframes, and interior support systems—are discussed to highlight the complementary roles of aluminum and magnesium in achieving vehicle-level lightweighting targets. Recent developments in alloy design, hybrid manufacturing, and intelligent process optimization are also reviewed, along with the technological challenges that continue to limit large-scale industrial adoption. The review concludes by identifying future research directions focused on advanced alloy formulations, integrated computational design, sustainable recycling pathways, and adaptive squeeze-casting control strategies for next-generation EV architectures.