Development of strong, formable, stainless and low-cost magnesium alloys for next generation cars

为下一代汽车开发坚固、可成型、不锈钢和低成本的镁合金

• 批准号: MR/T019123/2
• 负责人: Dikai Guan
• 金额: $ 93.49万
• 依托单位: University of Southampton
• 依托单位国家: 英国
• 项目类别: Fellowship
• 财政年份: 2022
• 资助国家: 英国
• 起止时间: 2022 至 无数据
• 项目状态: 未结题
• 来源: https://gtr.ukri.org/projects?ref=MR%2FT019123%2F2
• 关键词: Development; strong; formable; stainless; low

Light weighting is one of the biggest challenges facing manufacturers today and urgently required for next generation cars to increase fuel efficiency and reduce carbon emissions. Reducing a car's weight by 50 kg decreases emissions by up to 5g CO2/km and increases fuel economy by up to 2%. Being 75% and 33% lighter than steel and aluminium (Al), Mg is becoming more popular with automotive engineers. In theory, Mg alloys offer a promising solution for lightweighting in several industrial sectors. However, Mg components currently only constitute ~1% of a typical car's weight. This is attributed to long-standing issues with Mg alloys such as high production cost, low formability and high corrosion rate, compared to heavier Al and steels. Therefore, designing high performance and low cost Mg alloys is in great demand for automotive industry. Producing strong, formable, stainless and low-cost Mg alloys is recognised to be extremely difficult and has not to date been achieved. Traditional alloy design routes and manufacturing processing are not only time-consuming and not cost-effective, but also cannot guarantee production Mg alloys with high performance. In addition, the highly debated recrystallisation and deformation mechanisms, critical in optimising mechanical and physical properties of Mg alloys, need to be thoroughly explored and established.The overall objective of this fellowship is to develop new routes of alloy design, simultaneously developing innovative manufacturing processes, thereby producing strong, formable, stainless and low-cost Mg alloys(e.g., yield strength >300 MPa, Index Erichsen (I.E.) value indicating stretch formability >8mm, corrosion rate <0.4mg/cm2/day). This will be achieved by understanding how the alloying elements interact with each other and how the developed processes can be used to tailor multi-scale microstructures (e.g., alloys containing ultrafine grains (~1 microns) with weak texture). Equipped with vast state-of-the-art facilities covering alloying designing, manufacturing and processing, testing and characterisation, Royce@Sheffield and Sorby Centre will help me deliver a step change in the discovery and development of new Mg alloy systems, enabling concepts development from early, fundamental research right through to translation to industry and, crucially, covering Technology Readiness Levels (TRL) 1 to 6. Recently, a corrosion-resistant Mg-Li alloy was produced, but its high production cost and potential flammability still need to be considered before it can be commercially adopted. My goal is to push the boundaries of high-performance light Mg alloys yet further and I already have evidence that I can increase the strength and corrosion resistance of a commercial Mg alloy, currently approved by U.S. Federal Aviation Administration, without ductility loss using novel thermomechanical processing. This fellowship will address significant challenges in coupling high mechanical properties and corrosion resistance within a single alloy system.The fellowship aims to help industrial project partners accelerate the development of new advanced light alloys. New thermomechanical/manufacturing processes are exportable technology and will permit companies to develop new IP. My research will be further extended to develop products for aerospace, public transport and medical industries and ensure a low carbon economy in the UK. Most importantly, this fellowship will assemble a new UK team of engineering and microscopists with the aim of turning vulnerable Mg into reliable structural/medical materials, thereby accelerating the pace of light weighting in several industrial sectors.

轻量化是当今制造商面临的最大挑战之一，也是下一代汽车提高燃油效率和减少碳排放的迫切需求。将汽车重量减少50公斤，可减少高达5克二氧化碳/公里的排放量，并将燃油经济性提高2%。镁比钢和铝（Al）轻75%和33%，越来越受到汽车工程师的欢迎。从理论上讲，镁合金为几个工业部门的轻量化提供了一个有前途的解决方案。然而，镁成分目前仅占典型汽车重量的1%。这是由于镁合金长期存在的问题，如与较重的铝和钢相比，生产成本高，可成形性低和腐蚀速率高。因此，设计高性能、低成本的镁合金是汽车工业的迫切需求。生产坚固的、可成形的、不锈的和低成本的镁合金被认为是极其困难的，并且迄今为止尚未实现。传统的合金设计路线和制造工艺不仅耗时长、成本低，而且不能保证生产出高性能的镁合金。此外，在优化镁合金的机械和物理性能方面，备受争议的再结晶和变形机制需要彻底探索和建立。该奖学金的总体目标是开发新的合金设计路线，同时开发创新的制造工艺，从而生产出坚固，可成形，不锈和低成本的镁合金（例如，屈服强度>300 MPa，Erichsen指数（I.E.）表示拉伸成形性的值> 8 mm，腐蚀速率<0.4mg/cm 2/天）。这将通过理解合金元素如何彼此相互作用以及所开发的工艺如何用于定制多尺度微观结构（例如，含有具有弱织构的超细晶粒（~1微米）的合金）。Royce@谢菲尔德和Sorby中心配备了庞大的最先进设施，涵盖合金设计、制造和加工、测试和表征，将帮助我在新镁合金系统的发现和开发方面实现飞跃，实现从早期基础研究到转化为工业的概念开发，最重要的是，涵盖技术准备水平（TRL）1至6。最近，一种耐腐蚀的Mg-Li合金被生产出来，但其较高的生产成本和潜在的易燃性仍需要考虑，然后才能在商业上采用。我的目标是进一步推动高性能轻镁合金的界限，我已经有证据表明，我可以提高商业镁合金的强度和耐腐蚀性，目前已获得美国联邦航空管理局的批准，使用新的热机械加工，没有延展性损失。该奖学金将解决在单一合金系统中结合高机械性能和耐腐蚀性的重大挑战。该奖学金旨在帮助工业项目合作伙伴加速新型先进轻合金的开发。新的热机械/制造工艺是可出口的技术，将允许公司开发新的IP。我的研究将进一步扩展到为航空航天，公共交通和医疗行业开发产品，并确保英国的低碳经济。最重要的是，该奖学金将组建一个新的英国工程和显微镜团队，旨在将脆弱的镁转化为可靠的结构/医疗材料，从而加快几个工业部门的轻量化步伐。

项目成果

Thermodynamic Insights into the Oxidation Mechanisms of CrMnFeCoNi High-Entropy Alloy Using In Situ X-ray Diffraction.

• DOI: 10.3390/ma16145042
• 发表时间: 2023-07-17
• 期刊: MATERIALS
• 影响因子: 3.4
• 作者: Arshad, Muhammad;Bano, Saira;Amer, Mohamed;Janik, Vit;Hayat, Qamar;Huang, Yuze;Guan, Dikai;Bai, Mingwen
• 通讯作者: Bai, Mingwen

Magnesium Technology 2024

镁技术 2024

• DOI: 10.1007/978-3-031-50240-8_10
• 发表时间: 2024
• 作者: Yi H

Laser-directed energy deposition of a high performance additively manufactured (CoCrNi)94(TiAl)6 medium-entropy alloy with a novel core-shell structured strengthening phase

• DOI: 10.1016/j.addma.2024.103971
• 发表时间: 2024-01
• 期刊: Additive Manufacturing
• 影响因子: 11
• 作者: Xiaolin Bi;Ruifeng Li;Zijian Yuan;Jiangbo Cheng;Dikai Guan;Peilei Zhang

Three-dimensional study of grain scale tensile twinning activity in magnesium: A combination of microstructure characterization and mechanical modeling

镁晶粒拉伸孪生活动的三维研究：微观结构表征和机械建模的结合

• DOI: 10.1016/j.actamat.2023.119043
• 发表时间: 2023
• 期刊: Acta Materialia
• 影响因子: 9.4
• 作者: Zeng X

Dependence of microstructure evolution of novel CoreFlow™ aluminium alloy wire on wire diameter

• DOI: 10.1016/j.jmrt.2023.12.177
• 发表时间: 2023-12
• 期刊: Journal of Materials Research and Technology
• 作者: Liang Yuan;Xun Zeng;Xingjian Zhao;Yanheng Xie;Joao Gandra;Dikai Guan