A Novel Containerless Melting and Casting Process for Structural Cast Magnesium Alloys

该奖项的研究目标是开发一种生产高质量镁铸件的新技术。这项工作涉及先进的计算和实验方法，将导致开发一种新的电磁铸造工艺，并开发出一种足够通用的工艺模型，以适用于几种传统的电磁铸造和凝固工艺。研究方法将从开发熔化操作的综合数学模型发展到了解铸造变量对铸造镁合金组织和力学性能的影响。成果包括建模和分析工具、加工-显微组织-性能数据库的开发、研究结果的记录和传播、工程学生教育以及本科生的工程研究经验。如果成功，这项研究的结果将提供一系列计算工具，可用于优化金属的电磁熔化和铸造。这项研究还将提供一种生产高纯度、低缺陷含量和独特组织的铸件的方法。例子包括高活性且难以生产的轻质镁合金。本研究开发的计算工具将广泛适用于其他电磁熔铸技术，如头盖骨感应熔炼和电磁铸造。结果将被传播，以允许创造具有更高精度、降低成本、减轻重量和改善可回收性的商业设备。工程专业的研究生和本科生将从课堂教学和参与研究中受益。来自阿拉巴马大学和历史上的黑人学院和大学的本科生将被邀请为他们提供第一手的研究经验。

The research objective of this award is to develop a novel technology for producing high quality magnesium castings. The work involves advanced computational and experimental methods that will result in the development of a new electromagnetic casting process and of a process model that is general enough to apply to several conventional electromagnetic casting and solidification processes. The research approach will progress from the development of a comprehensive mathematical model of the melting operation to understanding of the influences of casting variables on the microstructures and mechanical properties of cast magnesium alloys. Deliverables include a modeling and analysis tools, development of a processing-microstructure-properties database, documentation and dissemination of research results, engineering student education, and engineering research experiences for undergraduates.If successful, the results of this research will provide a series of computational tools that can be used to optimize electromagnetic melting and casting of metals. This research will also yield a means to produce castings with high purities, low defect contents, and unique microstructures. Examples include light weight magnesium alloys which are highly reactive and difficult to produce. The computational tools developed in this research will be broadly applicable to other electromagnetic melting and casting techniques such as skull induction melting and electromagnetic casting. The results will be disseminated to allow the creation of commercial devices that have increased precision, reduced cost, reduced weight, and improved recyclability. Graduate and undergraduate engineering students will benefit through classroom instruction and involvement in the research. Undergraduate students from the University of Alabama and historically black colleges and universities will be engaged to provide them firsthand research experience.