Defect formation in light metal alloy castings

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Despite their many advantages, castings produced from aluminum alloys are prone to a number of solidification related defects include macro- and micro-void formation and oxide film entrainment, which if present in structural components can result in reduced fatigue and impact performance. In the case of wheels these defects can also result in cosmetic defects on the surface of the wheel.This proposal describes a Strategic Project in the area of Competitive Manufacturing and Value-Added Products and Processes with focus on Near-Net-Shape Casting Processes. This research proposal focuses on porosity and oxide film formation in aluminum alloy near-net shape casting and combines both experiments, and state-of-art numerical modeling. The experimental program will be aimed at: 1) generating an improved fundamental understanding of porosity and oxide film defect formation; and 2) providing data suitable for validation of the numerical models to be developed in the program. The numerical modeling will be aimed at: 1) helping to design the experimental program and interpret the results; and 2) provide tools for use by industry to minimize the occurrence of these critical defects. The program, run in partnership with Canadian Autoparts Toyota and Alcan, will contribute to the training of 3 Doctoral students, a Master of Applied Science student and a Post-Doctoral Fellow.