SBIR Phase I: Reinforcement of Lightweight Material Castings with Dissimilar Metals

SBIR 第一阶段：用异种金属增强轻质材料铸件

• 批准号: 0944442
• 负责人: Clause Xu
• 金额: --
• 依托单位: Hans Tech
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2010
• 资助国家: 美国
• 起止时间: 2010-01-01 至 2010-12-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=0944442&HistoricalAwards=false
• 关键词: SBIR; Phase; Reinforcement; Lightweight; Material

This Small Business Innovation Research (SBIR) Phase I project aims to advance the cast-on technology for the metal casting industry to produce lightweight metal composite castings. Cast-on method is a cost effective method for the reinforcement of casting with dissimilar metals but suffers from defect formation such as de-bond, oxidation, and porosity at the casting/reinforcement interface. The project combines the merits of the cast-on method and the latest high-intensity ultrasonic processing. The use of high-intensity ultrasonic vibration technique in the cast-on process detaches oxides and bubbles at the surfaces of the insert, drives them away from the reinforcement/casting interface, and enhances the metallurgical interaction of the castings with the reinforcement metal. Furthermore, the grain size in the casting adjacent to the bond is reduced significantly. As a result, a strong and defect-free metallurgical bond is produced between the reinforcement insert and the casting.The boarder impact/commercial potential of this project will be a breakthrough technology for the cast-on process and will increase the competitiveness of the U.S. metal casting, automotive, and defense industries in the global market, retaining or creating new jobs. This technology can be used to reinforce aluminum castings, magnesium castings, or castings of other lightweight materials for replacing heavy metal components for automotive, aviation, and defense applications, leading to significant energy savings, cost savings, and improved emission control. The U.S. transportation industry continues to focus on the increased use of lightweight alloys for weight reduction and energy savings. According to the data from the United States Automotive Materials Partnership (USAMP), a 15% weight reduction due to the use of lightweight components improves fuel efficiency by at least 10%. Decreasing fuel consumption by 10% reduces gasoline consumption in the United States by 10 billion gallons per year. This would translate into energy savings of 1,150 trillion Btu/year, a reduction of CO2 emissions by 200 billion lbs/year, and cost savings of $25 billion/year at current pump prices of $2.50/gallon.

该小型企业创新研究 (SBIR) 第一阶段项目旨在推进金属铸造行业的铸造技术，以生产轻质金属复合铸件。浇铸法是一种具有成本效益的异种金属铸件加固方法，但会在铸件/加固界面处形成脱粘、氧化和孔隙等缺陷。该项目结合了浇铸法和最新高强度超声波处理的优点。在铸上工艺中使用高强度超声波振动技术可以分离镶件表面的氧化物和气泡，驱使它们远离增强体/铸件界面，并增强铸件与增强体金属的冶金相互作用。此外，邻近结合处的铸件中的晶粒尺寸显着减小。结果，在增强嵌件和铸件之间产生了牢固且无缺陷的冶金结合。该项目的边界影响/商业潜力将成为铸造工艺的突破性技术，并将提高美国金属铸造、汽车和国防工业在全球市场上的竞争力，保留或创造新的就业机会。该技术可用于增强铝铸件、镁铸件或其他轻质材料铸件，以替代汽车、航空和国防应用中的重金属部件，从而显着节省能源、成本并改善排放控制。美国交通运输业继续关注增加轻质合金的使用以减轻重量和节能。根据美国汽车材料合作伙伴组织（USAMP）的数据，由于使用轻量化部件，重量减轻15%，燃油效率至少提高10%。燃料消耗减少 10%，美国每年汽油消耗量将减少 100 亿加仑。这意味着每年可节省 1,150 万亿英热单位的能源，每年减少 2000 亿磅的二氧化碳排放，以目前每加仑 2.50 美元的泵价计算，每年可节省 250 亿美元的成本。