Development of novel manufacturing route for automotive suspension parts

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In order to reduce the weight and the consumption of car, more vehicle parts have been manufactured with lightweight alloys. Al castings have been used in the powertrain and, more recently, as sheet & extrusions in the car body. Applications in the suspension components is also a new trend as the benefit of Al in these components is the reduction in weight together with improved road handling and increased noise/vibration dampening. The industrial partner of the present projet, Raufoss, is a supplier of automotive suspension components in Al-Si-Mg alloy manufactured using a casting / extrusion and forging route. The extrusion and heat-treatment portion of the manufacturing route allow fine grained material to be produced, but it is a time/energy consuming process which is costly. In order to improve the cost effectiveness and maintain Raufoss strategic position as a manufacturing leader, alternate routes have to be developed. In the present project, the possibility of using a direct-chill (DC) cast rod to replace the conventional casting extrusion / heat treatment steps will be investigated. As different microstructures, grain structures, and heterogeneities will be generated with this castings technology, every step of the production route will have to be investigated and optimized to enhance the final properties of the produced parts in term of fatigue properties. The knowledge generated in this project will give the industrial partner a competitive edge in possessing a cost effective forging process for suspension components, the technology will enable them to develop new business, and to innovate to secure higher market share. HQP trained in this project will have key expertise in the lightweight transport applications (materials production, extrusion, fabrication, forming and applications) and will help keep these key industries in Canada.