Advances in high-strength and high-thermal conductivity cast magnesium alloys: Strategies for property optimization

High-strength, high-thermal conductivity casting Mg alloys are increasingly crucial in electronics industries. This study focuses on developing novel strategies for the fabrication and performance optimization of high-strength and high-thermal conductivity Mg alloys through the refinement of casting processes and associated parameters. First, it systematically examines the significant impacts of alloying elements, grain boundaries, dislocations, texture, and service temperature on these properties, and provides strategies for optimizing the thermal conductivity and mechanical properties. Next, the effect of casting parameters on alloys is thoroughly analyzed. Parameters such as the cooling rate, casting temperature, mold design, and external physical fields play a vital role in alloy densification, grain size, and uniformity. Optimal cooling rates and casting temperatures can effectively reduce casting defects while enhancing both mechanical properties and thermal conductivity. Finally, the potential of various casting processes, including gravity casting, die-casting, as well as squeeze casting, is discussed for the development of high-mechanical properties, high- thermal conductivity Mg alloys. This work offers a comprehensive theoretical foundation for studying high-performance cast Mg alloys and identifies future research directions and challenges in casting processes and material design, providing a solid base for further exploration in related fields.