Photo: GSA
Reducing vehicle weight without compromising strength or durability remains one of the central challenges in mobility. In 2020, GSA Gesenkschmiede Schneider GmbH received the MATERIALICA Gold Award in the category Material for a forged aluminium-magnesium composite that combines the strengths of two lightweight metals.
Magnesium is around 30 percent lighter than aluminium, but its susceptibility to corrosion limits its use in demanding components. GSA’s solution uses magnesium as the lightweight core, protected by an outer layer of corrosion-resistant aluminium. The two materials are joined through a magnetic forming process and subsequently forged into complex, highly load-bearing components.
Forging is crucial to the concept. It produces higher mechanical properties and creates a favourable fibre flow within the component, increasing strength. At the same time, the process places high demands on manufacturing: temperature must be controlled precisely, the forging tools must be preheated, forming speeds kept low and contact and handling times reduced to a minimum.
The result is a stable material composite that can deliver weight savings of up to 55 percent compared with steel components. According to the award submission, potential savings amount to around eight percent in passenger-car drivetrain and chassis applications and up to twelve percent in relevant truck applications. Further possibilities include lightweight pistons, valves and connecting rods.
Although the innovation was recognised in 2020, its relevance has only increased. Electric vehicles need to compensate for battery weight, commercial vehicles benefit directly from every kilogram of additional payload, and lower mass can reduce energy consumption throughout a vehicle’s operating life. The aluminium-magnesium composite demonstrates how intelligent material combinations and advanced manufacturing processes can unlock completely new design possibilities.
Which material innovation will shape the next generation of products?
Submit your development to the MATERIALICA Design + Technology Award 2026 in the categories Material, Product, Process or CO₂ Efficiency.
Application deadline: July 31, 2026
https://www.emove360.com/awards/materialica-award/
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