Magnesium alloy is a lightweight material which is potential to decrease the weight of auto body for lightweight. Experiments were performed to study the mechanics characterization of AZ61 magnesium alloy at normal temperature. The steel structure of an auto body was improved with AZ61 magnesium alloy as a case study. The weight of the magnesium alloy auto body parts decreases dramatically. The finite element method and multi-body dynamic method were applied to simulate the front impact of the magnesium alloy auto body and the occupant restraint system. The results of the magnesium alloy auto body were compared to the results of the original auto body according to the China New Car Assessment Program (C-NCAP) test. The results show the feasibility of the application of magnesium alloy on auto body based on the performance of stiffness, modal and safety of front impact.
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