In this study, redesigning for equal functional properties and rapid prototyping of hot forged automotive parts based on commerically available wrought magnesium alloys (AZ80) and composites ...(AZ80/SiC/12p) were performed. To achieve the same functional properties in a forged automotive component irrespective of the structural material selected, an automotive connecting rod, currently mass-produced in aluminium alloy 6061, was redesigned for usage of wrought magnesium alloy (AZ80A) and particle reinforced magnesium alloy matrix composite (ZC71/SiC/12p). By applying conventional hot forging technology, prototype connecting rods were forged, trimmed and heat treated on a semi-industrial scale. The microstructure of both as-extruded and hot forged species was examined and the tensile properties of AZ80, ZC71/SiC/12p, 6061 and 6061/SiC/15p testing bars machined from hot forged connecting rods were measured. Weight reduction in the redesigned connecting rods was determined and the submission of magnesium and aluminium-based materials for steel was compared in terms of cost in order to demonstrate the main economic advantages.
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