Shrinkage-related Casting Defects in Light Metal Alloys

汽车和航空航天行业对新的或改进的轻金属部件的需求继续受到通过减轻重量来提高燃油经济性和性能的需求。铸造铝合金产品通过更换汽车发动机中的铁基部件和悬架部件中的零件加固，显示出良好的市场渗透率。虽然轻金属的使用可以提高车辆的能源效率，但需要在上游工艺中不断改进，以提高产品质量，提高产量和生产能源效率。通过减少与收缩相关的铸造缺陷来改进形状铸造工艺已被选为NSERC Discovery补助金的考虑因素。*建议的研究计划侧重于发展与模型(二元)和商业合金形成三种铸造缺陷的敏感性相关的新的基础知识：i)宏观偏析、ii)宏观疏松和iii)表面凹陷。所有这三种缺陷都与凝固过程中与收缩有关的液态金属补缩密切相关。提出了一种实验铸造和数学建模相结合的方法，以产生必要的知识并开发计算工具来量化金属合金形成缺陷的敏感性，这些缺陷与基于缩松的液态金属补缩有关。加拿大在金属铸造技术方面拥有竞争优势，包括通过经验和持续研究开发的一次和二次(形状铸造)工艺。与铸造行业相关的新知识的持续发展对于保持这一竞争优势至关重要。发展对与收缩相关的液态金属补缩缺陷的更基本的了解，并开发工具来定量预测它们的形成，最终将带来更好的铸件和更高效的铸造工艺。这将使加拿大制造公司在面临来自离岸制造商越来越大的压力的同时保持竞争力。

The demand for new or improved light metals components in the automotive and aerospace industries continues to be driven by the need for improved fuel economy and performance through weight savings. Cast aluminum alloy products have shown good market penetration by replacing ferrous-based components in automotive engines and through part consolidation in suspension components. While light metals usage may advance vehicle energy efficiency, continuous improvement is needed in the upstream processes to enhance product quality and increase yield and production energy efficiency. The improvement of shape casting processes through the reduction of shrinkage-related casting defects has been selected for consideration in this NSERC Discovery Grant.******The proposed research program is focused on developing new and fundamental knowledge related to the susceptibility of model (binary) and commercial alloys to form three casting defects: i) macrosegregation, ii) macroporosity, and iii) surface depressions. All three of these defects are intimately related to shrinkage-related liquid metal feeding during solidification. A combined approach involving experimental castings and mathematical modeling is proposed to generate necessary knowledge and to develop computational tools to quantify the susceptibility of metallic alloys to form defects related to shrinkage-based liquid metal feeding.******Canada enjoys a competitive advantage in metal casting technology, including primary and secondary (shape casting) casting processes, developed through experience and sustained research. The continued development of new knowledge relevant to the casting industry is critical to maintaining this competitive advantage. Developing a more fundamental understanding of shrinkage-related liquid metal feeding defects and developing tools to quantitatively predict their formation will ultimately lead to better castings and more efficient casting processes. This will enable Canadian manufacturing companies to remain competitive while facing increasing pressure from off-shore manufactures.