Daochen Introduces Mineral Oil Cooling Solution for Magnesium Alloy: Eliminating Leakage Risks and Redefining Safe Die Casting

Wuhan Die Casting Annual Conference Highlights Magnesium Alloy Safety Solutions

 At the 2026 National Die Casting Industry Annual Conference held in Wuhan from March 25–27, magnesium alloy emerged as the focal point of discussions. Widely recognized for light weighting in electric vehicles, magnesium also plays a critical role in robotics, aerospace, and low-altitude aircraft applications.

However, industry adoption faces a persistent safety challenge: over 30% of conventional water-cooled systems risk leakage, which, when exposed to molten magnesium, can result in explosive hazards and production downtime. Daochen’s mineral oil-based cooling technology provides a reliable solution to this safety concern.

 Oil Jet Cooling System for a leading magnesium alloy manufacturer

Industry Context: Magnesium’s Growth and Challenges

•Market: The demand for magnesium in EVs is surging, with usage per vehicle now targeting 35–45 kg. OEMs such as Tesla, BYD, and FAW are already producing magnesium components including steering wheel skeletons, crossbeams, and battery housings. Aerospace, robotics, and other emerging industries are also expanding magnesium applications. Magnesium offers 25–37% weight reduction compared to aluminum, along with significant cost savings.

 •Policy Support: Lightweight materials are prioritized under China’s carbon neutrality strategy. Abundant domestic magnesium resources and stable low prices create favorable 

conditions for large-scale adoption. 

•Technical Challenges: Conventional water cooling systems are prone to leakage, boiling, uneven temperature control, and corrosion, limiting magnesium’s scalability from lab to production.

Daochen Solution: Mineral Oil Cooling for Safe, Efficient Magnesium Die Casting

Daochen, the only company in the industry that is capable of independently manufacturing a full range of mold thermal management systems, began developing magnesium-specific cooling technology in 2008.

After more than a decade of on-site testing and continuous optimization, we have provided deep support to multiple leading magnesium alloy users, with hundreds of stable installations.

Daochen has launched China’s first mineral oil-based cooling system for thick-walled magnesium parts, such as motor housings. This dual-unit system—combining oil chillers and oil temperature units—was unveiled at last year’s Shanghai International Die Casting Exhibition and has since been successfully adopted by well-known die casting companies, receiving high market recognition.

Oil Jet Cooling System for a leading magnesium alloy manufacturer

Key Considerations:

Magnesium die casting involves high temperatures and flammable, potentially explosive environments, placing extreme demands on cooling media. Conventional heat-transfer oils often underperform under high temperatures and long-term circulation; their high viscosity and poor flow can lead to micro porosity and shrinkage defects, seriously impacting product quality and even posing safety risks.

Daochen’s proprietary mineral oil cooling fluid is specially formulated for magnesium alloys, high-temperature die casting conditions, and mold channel structures. With flow characteristics four times better than traditional oils—close to water—it quickly removes heat from molds, achieving efficient and uniform cooling.

By addressing potential hazards at the source, this solution ensures long-term, stable operation in magnesium production lines.

Zero Explosion Risk — A Safety Lock for Scaled Production

Safety remains the top priority for magnesium adoption. Daochen’s system eliminates the industry’s greatest hazard at its source:

      •  The mineral oil does not react violently with molten magnesium. Even in the event of a leak, it will not ignite or explode, completely removing the fatal “water-meets-magnesium” risk. It is suitable for high-temperature, high-pressure production of large magnesium parts such as floor panels and electric drive housings.

      •   The system uses a corrosion-free medium, preventing mold channel corrosion, significantly extending mold life, and avoiding production losses that can reach millions due to mold failure, providing a solid safety foundation for production expansion.

Precise Temperature Control ±0.5°C — Meeting High-End Magnesium Process Requirements

ases presented at the conference highlighted the near-extreme precision required for semi-solid casting and thin-walled magnesium parts.

Conventional water cooling suffers from boiling and temperature variations, limiting quality. Daochen’s solution directly addresses these issues:

         •       Dual-unit operation (oil chiller + oil temperature unit) achieves ±0.5°C precise control, without boiling or temperature differences, perfectly suited for semi-solid magnesium and high-pressure die casting, improving thin-walled part yield by over 15% and easily achieving weight reductions of more than 25%.

         •       Supports a wide temperature range from -20°C to 350°C, with 22% higher heat transfer efficiency than water cooling. This meets the demanding requirements of automotive electric components, 3C precision parts, and aerospace components.

Visible Cost Reduction and Efficiency Gains

Magnesium alloy can reduce costs by more than 35% compared with aluminum, provided process stability is ensured. Daochen’s system converts this potential into actual benefits:

         •       Reduces maintenance downtime by 80%, cutting hidden costs by 30%

         •       Enables mass production of steering wheel skeletons, display back plates, and other components, doubling production capacity upon project launch

         •       Recyclable mineral oil supports carbon neutrality and green manufacturing in EV, 3C, and aerospace sectors

Enhanced Safety Monitoring：Mold cavity leakage detection, core pin breakage detection, and full-dimension monitoring of temperature, pressure, and flow

Integrated Keyence ultrasonic flow monitoring provides non-contact intelligent sensing, creating a closed-loop safety system throughout the cooling lifecycle, eliminating potential leakage hazards

Ensuring Safe Growth for the Magnesium Industry

With 20 years of technical expertise, multiple national patents, and over 350 advanced machining and testing devices, Daochen is a trusted partner for OEMs and leading die casting companies. Real-world cases demonstrate that the magnesium boom should not be hindered by safety concerns.

Looking ahead, as magnesium alloy penetrates automotive, robotics, and low-altitude aircraft applications, Daochen will continue to innovate thermal management technologies, providing safer, more efficient solutions to help companies capture light weighting benefits and expand production steadily.