Phenomenological investigations in light metal casting

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The rapidly evolving energy crisis provides an increased impetus for developing appropriate shaping processes for light alloys in the automotive and aerospace industries. Magnesium alloys are ~33% lighter than aluminum alloys and ~75% lighter than steel. This research program proposes to build upon extensive and pioneering research experience and knowledge in conventional and novel casting processes to develop magnesium alloys comparable to aluminum alloys in castability, minimal defects and superior in-service properties. It seeks to develop an enhanced understanding of the origin of casting defects and the role of various inclusions and other microstctural features with a view to improving melt cleanliness, heat flow and fillability. Also, it will result in an improvement of the the high temperature properties of magnesium alloys through suitable combination of alloying additions. Further, it seeks a better understanding of hot tearing during solidification of light alloys through measurement of associated residual strains and iterative modelling based on actual process parameters. It is envisaged that this can enable development of reliable criterion functions for predicting hot tear susceptibility.