Development of Nanostructured Coatings for Lightweight Materials with Enhanced Properties

开发具有增强性能的轻质材料纳米结构涂层

• 批准号: RGPIN-2014-06102
• 负责人: Nie, Xueyuan
• 金额: $ 2.11万
• 依托单位: University of Windsor
• 依托单位国家: 加拿大
• 项目类别: Discovery Grants Program - Individual
• 财政年份: 2018
• 资助国家: 加拿大
• 起止时间: 2018-01-01 至 2019-12-31
• 项目状态: 已结题
• 来源: https://www.nserc-crsng.gc.ca/ase-oro/Details-Detailles_eng.asp?id=660934
• 关键词: Development; Nanostructured; Coatings; Lightweight; Materials

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.

汽车工业一直在寻求一种更轻的材料来代替重的材料来减轻重量。例如，有人提出用铝（Al）发动机代替重型铸铁发动机，用铝薄板代替重型钢板制作汽车车身面板。然而，这种替代品必须面临巨大的技术挑战。在这个拟议的研究项目中，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，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项目：1)通过化学掺杂和表面形貌处理改善摩擦性能的铝硅合金氧化物涂层，例如用于发动机缸体和活塞；隔热板和换热器用铝箔柔性陶瓷涂层；3)开发具有增强抗冲击性的轻质纳米复合材料，例如用于车辆装甲。由于纳米结构涂层技术的应用，轻量化铝材料可以扩展到更广泛的应用范围。轻量化、低摩擦和改进的热管理将有利于车辆提高燃油效率和减少二氧化碳排放。**将使用扫描电子显微镜（SEM）、透射电子显微镜（TEM）和x射线衍射（XRD）分析来识别层压板之间的表面形貌、微观结构、晶粒尺寸和界面。拉伸、压缩和弯曲试验将用于研究陶瓷/金属复合材料的机械强度。将进行摩擦和磨损测试以及表面硬度和冲击测试（针对表面划痕，凹痕和冲击）。测量了氧化物/铝复合材料的导热系数和发射率。涂料的性能不仅要在一套测试板上进行评估，还要在实际部件上进行评估。在这个特殊的项目中，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，以及加强铝车身面板的抗冲击和抗压痕性能。所开发的工艺也适用于镁合金和钛合金。**质量和摩擦的减少以及热管理与燃油效率直接相关。如果有20%的车辆使用这种涂层技术，那么燃油效率将提高2%，每年将节省30亿升燃料。如果在加拿大生产相同比例（20%）的汽车（加拿大每年生产160万辆汽车）使用先进的技术，每辆车可以创造30美元，那么可以创造100个高薪工作岗位。因此，这个拟议的项目将对加拿大的环境保护和创造就业机会非常重要。该研究项目将为加拿大汽车和制造业提供HQP培训（4名博士和4名硕士生）和技术进步。