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just replace it with a new fan. It isn't worth messing with and can cost more in the end. The aluminum ones weigh 33% more so that is more mass moving at a high rate of speed which will wear out bearings and put strain on the belts and crank when speeds change quickly. Potential rob you of power. I have a 30 year old fan with 144k miles which remains perfect condition on my race car.
These fans should not just crack by themselves unless someone did something. Magnesium is quite strong and will last just as long as aluminum if made properly and the coating isn't damaged.
Are you sure the casting is broken or is it the coating? I have grit blasted fans that showed cracks like your second picture and it ended up just being the paint that was showing signs of cracking. Once removed the indication or crack disappeared and did not show up as a problem when penetrant inspected.
For some reason my photos which speak more than words.
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Anthony PCA affiliate '77 member '83 '90 3.8 RS tribute, 91 C4 converted to C2,'93 964 C2, '93 928 GTS M '94 Turbo 3.6, '15 Boxster GTS M,16 GT4,23 Macan GTS,
Gone worth mentioning '71 E '79 SC, '79 built to '74 3.0 RS tribute (2390 # 270 hp), '80 928 euro 5 speed, '74 2.0l 914, '89 944 S2,'04 Cayenne TT '14 boxster, '14 Cayenne GTS 14 Cayman S, 18 Macan GTS many others
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