Development of Nanostructured Coatings for Lightweight Materials with Enhanced Properties

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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.