Ultra high strength Al & Mg alloys, hard coatings and their applications in engine blocks and head covers

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The project, entitled Ultra High Strength AI & Mg Alloys, Hard Coatings and Their Applications in Engine Blocks & Head Covers, is to develop new casting alloys and coating materials and processing technologies which enable use of light alloys to make engine components to have the reduced weight and friction for better fuel economy and lower emission. The target prototype engines are a downsized 13 (three cylinders) engine (in North America) and an 14 (four-cylinder) engine (in China) which will be turbocharged for producing 150 horsepower (power density: 100-150 hp/L). The lightweight is even more important for downsized engines, thus in this project a novel high strength aluminium alloy containing Cu, Ni and Ti will be developed with an optimal advanced squeeze casting process for engine blocks, the heaviest components in an automotive passage car; a modified AJ62 magnesium (Mg) alloy and processing will also be developed to produce engine head covers. A 10% weight and friction reduction can lead to 6-8% gain of auto fuel economy, greatly benefiting cleaner environment. With the advanced light weight materials and coating technologies developed in this project, lightweight components can withstand heavy dynamic loading and harsh operating conditions during use of the turbocharged downsized engines. With supports from the Canada-China Research Collaboration Initiative to academic institutions and automotive industrial partners, multiple-ways collaborations between the two countries will make the industrial partners to have technical and commercial advantages, including securing new technology and product, increasing sales, and/or accessing new markets, leading to the creation of high paying jobs, hiring new employees and/or increased revenues. Upon the successful completion of the proposed project, there is a high probability that the companies will be the end users of the developed technologies. The new alloys and coatings technology can be applied for many other industries. as well. Therefore, the project will lead to significant and measurable economic societal impact to the economy of both, countries.