Lightweight multi-layer composite metal sheet products for the automotive industry

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The present proposal aims to explore the production of a new lightweight multi-composite metal sheet product for the automotive industry. The multi-layer product, as a combination of light metal alloys, aluminum and magnesium sheets, with (or without) an interior thin sheet of light-weighted steel (HSHD), is to be used for auto body-in-white construction, so as to provide strength for crashworthiness with simultaneous light weighting. Using the Horizontal Single Belt Casting (HSBC) process with in-line rolling, we will cast and meld two alloy streams together, so as to partially intermix the rapidly freezing molten alloys, followed by in-line rolling. The rapid cooling of the thin sheet on the moving water cooled metal substrate, onto which the multi-alloy liquids would be delivered, will eliminate the inverse macro-segregation effects encountered using the DC casting with aluminum alloys. The process of casting a thin sheet of magnesium will eliminate rolling difficulties encountered when magnesium thicknesses have to be reduced. We will develop a new feeding system, so as to sequentially feed two streams of liquid metal alloys; aluminum-based, then magnesium-based, onto the belt, one following the other. Taking into account buoyancy effects, we propose that a thin aluminum layer, topped with a magnesium layer should be our first attempt at a two-layer product. We will then attempt to cast a three layers, a HSHD steel/Mg/Al sheet product, and test its integrity. The upper, magnesium surface will be protected from oxidation, during solidification. CFD (Computational Fluid Dynamics) calculations will be performed using our SGI 288 core, High Performance Computer Cluster, predicting the way in which the liquid metal flows become rapidly iso-kinetic with the belt, to form a thin composite sheet product. The new composite properties will be fed into the Integrated Computational Materials Engineering (ICME) database of the Ford Motor Company, together with our modelling of the microstructure and properties, for comparison, and for validation. The outcome of this project is expected to bring a new product/technology to Canada's automotive industry, and to provide it with the necessary HQP.