Process optimization for high integrity magnesium automotive components

高完整性镁汽车部件的工艺优化

• 批准号: 239080-2010
• 负责人: Hu, HongfaHenry
• 金额: $ 2.91万
• 依托单位: University of Windsor
• 依托单位国家: 加拿大
• 项目类别: Discovery Grants Program - Individual
• 财政年份: 2015
• 资助国家: 加拿大
• 起止时间: 2015-01-01 至 2016-12-31
• 项目状态: 已结题
• 来源: https://www.nserc-crsng.gc.ca/ase-oro/Details-Detailles_eng.asp?id=570565
• 关键词: Process; optimization; integrity; magnesium; automotive

Over the past 15 years, magnesium (Mg) usage in automobiles has significantly increased by about 15% annually. The average Mg content in the 2007 model cars was about 6 kg, and is expected to increase to 160 kg by 2020. Currently, Mg automotive applications are produced by conventional high pressure die casting (HPDC) processes, which result in materials with high porosity content and low strengths. Recent studies have demonstrated that the squeeze casting process is able to significantly eliminate porosity and other casting defects in magnesium alloys. However, squeeze casting is relatively costly compared with conventional HPDC due to higher process operation and tooling costs. To maximize the engineering performance and quality of Mg squeeze castings at a competitive cost, the squeeze casting process needs to be optimized. The proposed project intends to develop an optimal technology for manufacturing integrity cast Mg automotive components such as control arms and knuckles, which are thick-wall castings with various cross section thicknesses. The work will include development and fabrication of an integrated step-die incorporating advanced transducers and sensors for pressure and temperature measurements, design detailed experimental matrices by taking into consideration essential process parameters, analyses of microstructure, mechanical and corrosion behaviours of squeeze cast conventional (Mg-Al) and high temperature Ca and/or Sr-containing Mg alloys, and optimization of the process by employing an appropriate optimization methodology with comprehensive assessment of the properties of various alloys. The outcome of the project will help maintain Canada's leadership in the world in producing light weight Mg automotive components since Canada is presently hosting the largest die casting producers of Mg in the world with the presence of Meridian Lightweight Technologies in Ontario and TriMag in Quebec. The success in the development of new processes for potential advanced components will lead to an increase in Mg casting shipment in Canada as well as an expansion of world-wide use of Canadian value-added Mg products.

在过去的15年里，镁在汽车中的使用量以每年约15%的速度显著增长。2007年车型的平均镁含量约为6公斤，预计到2020年将增加到160公斤。目前，镁合金的汽车应用是通过传统的高压铸造(HPDC)工艺生产的，这导致材料的孔隙率高而强度低。最近的研究表明，挤压铸造工艺能够显着消除镁合金的气孔和其他铸造缺陷。然而，与传统的HPDC相比，挤压铸造的成本相对较高，因为工艺操作和工具成本较高。为了以具有竞争力的成本最大限度地提高镁合金挤压铸件的工程性能和质量，需要优化挤压铸造工艺。 该项目旨在开发一种制造整体式铸造镁合金汽车部件的最佳技术，例如控制臂和转向节，这些部件是具有不同横截面厚度的厚壁铸件。这项工作将包括开发和制造集成步进模具，其中包括用于压力和温度测量的先进传感器和传感器，通过考虑基本工艺参数来设计详细的实验矩阵，分析挤压铸造常规(镁铝)和高温钙和/或含锶镁合金的组织、机械和腐蚀行为，以及通过采用适当的优化方法并综合评估各种合金的性能来优化工艺。 该项目的成果将有助于保持加拿大在生产轻质镁汽车零部件方面的世界领先地位，因为加拿大目前拥有世界上最大的镁压铸生产商，在安大略省拥有子午线轻量化技术公司，在魁北克拥有TriMag公司。为潜在的先进部件开发新工艺的成功将导致加拿大镁铸件发货量的增加，以及加拿大附加值镁产品在世界范围内的扩大使用。