Defect formation in light metal alloy castings

尽管铝合金铸件有许多优点，但它们容易产生许多与凝固有关的缺陷，包括宏观和微观空洞形成和氧化膜夹带，如果存在于结构部件中，可能导致疲劳和冲击性能降低。在车轮的情况下，这些缺陷也会导致车轮表面的外观缺陷。该提案描述了一个战略项目，在竞争制造和增值产品和工艺领域，重点是近净形铸造工艺。本研究计划主要研究铝合金近净形铸件的孔隙率和氧化膜的形成，并结合实验和最先进的数值模拟。实验计划将旨在：1)提高对孔隙度和氧化膜缺陷形成的基本理解；2)为程序中将要开发的数值模型的验证提供合适的数据。数值模拟的目的是：1)帮助设计实验方案和解释实验结果；2)提供工具供工业界使用，以尽量减少这些关键缺陷的发生。该项目由加拿大丰田汽车公司和加拿大铝业公司合作开展，将培养3名博士生、1名应用科学硕士和1名博士后。

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.