Development of Nanostructured Coatings for Lightweight Materials with Enhanced Properties

汽车工业一直在寻求一种更轻的材料来代替重材料以减轻重量。例如，已经提出用铝（Al）发动机代替重型铸铁发动机，并且用铝板代替重型钢板用于车身面板。然而，这种替代品必须面临巨大的技术挑战。在这项拟议的研究计划中，研究的目标是开发纳米结构涂层，为铝合金提供增强的多功能性，如高表面硬度，高耐磨性，低摩擦和所需的热管理性能。该研究计划将包括三个子计划：1）通过化学掺杂和表面形貌操纵改善Al-Si合金的摩擦学性能的氧化物涂层，例如，发动机缸体和活塞的应用; 2）用于热屏蔽和交换器的铝箔上的柔性陶瓷涂层;和3）具有增强的抗冲击性的轻质纳米层压材料的开发，例如，车辆装甲。纳米结构涂层技术的应用使轻质铝材料的应用范围更加广泛。通过扫描电子显微镜（SEM）、透射电子显微镜（TEM）和X射线衍射（XRD）分析，可以确定层压板的表面形貌、微观结构、晶粒尺寸和层压板之间的界面。将进行拉伸、压缩和弯曲试验，以研究陶瓷/金属复合材料的机械强度。将进行摩擦和磨损试验以及表面硬度和冲击试验（针对表面划痕、凹痕和冲击）。测量了氧化物/Al复合材料的热导率和发射率。涂层的性能将不仅在一组测试试样上进行评价，而且在实际组件上进行评价。在这个特定项目中，涂层的高性能优势包括减少摩擦和改善铝发动机的摩擦学特性，增强铝片（隔热板）和板（热交换器）的热管理性能，以及增强铝车身板的抗冲击和抗压痕性能。开发的工艺也适用于镁和钛合金。质量和摩擦减少以及热管理与燃油效率直接相关。如果20%的车辆使用拟议的涂层技术，导致燃油效率提高2%，每年将节省30亿升燃油。如果在加拿大生产的相同比例（20%）的汽车（加拿大年产160万辆汽车）使用开发的技术，创造30美元/辆，可以创造100个高薪工作岗位。因此，该项目对加拿大的环境保护和创造就业机会具有重要意义。该研究项目将提供HQP培训（四名博士）。和四名硕士生）和加拿大汽车和制造业的技术进步。

Automotive industry has been continuously seeking a lighter material to replace a heavy material for weight reduction. For instance, aluminium (Al) engine has been proposed to replace heavy cast iron engine, and Al sheet is used to replace heavy steel sheet for car body panel. However, such replacements have to face tremendous technical challenges. In this proposed research program, the objective of research is to develop nanostructured coatings to provide aluminium alloys with enhanced multifunctionality, such as high surface hardness, high wear resistance, low friction, and desired thermal management properties. The research program will include three subprograms: 1) Oxide Coatings on Al-Si Alloys with Improved Tribological Properties through Chemical Doping and Surface Morphology Manipulation for, e.g., applications of engine block and piston; 2) Flexible Ceramic Coatings on Al Foils for Heat Shield and Exchanger; and 3) Development of Lightweight Nanolaminated Materials with Enhanced Impact Resistance for, e.g., vehicle armouring. Due to the nanostructured coatings technology, lightweight Al materials can extend their applications to a wider scope. The lightweight, low friction and improved thermal management will benefit vehicles to increase fuel efficiency and reduce CO2 emission.Scanning Electron Microscopy (SEM), Transmission Electron Microscopy (TEM) and x-ray diffraction (XRD) analysis will be used to identify surface morphology, microstructure, grain sizes and interfaces between laminates. Tensile, compression and bending tests will be carried out to investigate mechanical strengths of the ceramic/metallic composite materials. The friction and wear tests as well as surface hardness and impact tests (against surface scratch, dent and impact) will be performed. The thermal conductivity and emissivity of the oxide/Al composite materials will be measured. The performance of the coatings will be evaluated not only on set of testing coupons but also on actual components. High-performance benefits of the coatings in this particular project include the reduction of friction and improvement of tribological characteristics for Al engines, enhancement of thermal management property for Al sheet (heat shields) and plates (heat exchangers), and strengthening of impact and indentation resistance of Al car body panels. The developed process would be also applicable to magnesium and titanium alloys. Mass and friction reduction as well as thermal management are directly related to fuel efficiency. If 20% vehicles use the proposed coating technology, leading to say 2% improved fuel efficiency, 3 billion litres of fuel will be saved each year. If the same percentage (20%) vehicles produced in Canada (1.6 million vehicles annual production in Canada) use the developed technology creating $30 dollars/vehicle, 100 highly paid jobs can be generated. Therefore, this proposed project will be very significant in environmental protection and job creation for Canada. The research project will provide the HQP training (four Ph.D. and four Master's students) and technical advancement in Canadian auto and manufacturing sectors.