Evaluation and development of enabling technologies for lightweight automotive structural cast components with wrought aluminum and high performance magnesium alloys

该项目的动机是通过在底盘和车身结构部件中使用更多的Al和Mg** 合金来降低汽车的总重量;从而减少燃料的使用和对环境有害的CO2气体的排放。在汽车底盘和车身结构中引入铝和镁将需要合金的上级机械性能和性能远远超过汽车结构部件的严格安全要求。可用的Al和Mg铸造合金不满足这些安全要求，其中屈服强度超过300 MPa和伸长率至少10%是强制性的。实现汽车轻量化多材料解决方案的一个关键 ** 特征是能够成功地将这些 ** 部件连接在一起，并具有耐腐蚀性和接头强度劣化。铸造是铝合金和镁合金最经济可行的生产工艺。铝铸造合金和技术的最新进展已经证明了近净形铸造铝锻造合金的有效可行性，其机械性能和性能远远上级铸造合金。该联合项目旨在开发此类工艺和技术，以实现某些关键结构性汽车部件的原型设计。受控 ** 扩散凝固（CDS）、烧蚀铸造和使用高压压铸（HPDC）的半固态加工 ** 工艺将对三个系列的Al锻造合金（即6xxx和7 xxx系列合金）进行严格评估。意大利特伦托的研究小组将致力于开发6xxx合金系列，加拿大的研究小组将致力于7 xxx合金系列。此外，本项目还将沿着潜在的合金开发，对 ** 消融铸造工艺中某些高性能镁合金的铸造进行评估，以重新设计 ** 现有合金，使其更好地适应消融铸造工艺，从而最大限度地提高铸造 ** 部件的特性和性能。该项目的另一项任务是开发和优化一种新的异种金属连接工艺，** 在镦粗突起连接中，基于一种正在申请专利的工艺，将联合收割机铸造镁部件与 ** 本身以及其他AI和钢部件结合起来。这一举措将包括开发最佳的突起设计 ** 以及最佳的加热和锻造工艺，以镦粗突起并将两种材料锁定在一起。

The motivation for this project initiative is to reduce the overall weight of the automobile by utilizing more AI and Mg**alloys for both the chassis and body structure components; thereby, leading to reduction in the use of fuel and emission**of harmful C02 gas to the environment. The introduction of AI and Mg in the chassis and body structure of a car would**necessitate far superior mechanical properties and performance of the alloys to surpass the stringent safety**requirements for structural automotive components. The available AI and Mg casting alloys do not meet these safety**requirements wherein an yield strength in excess of 300 MPa and an elongation of at least 1 0% is mandatory. A critical**feature in achieving a light weight multi-material solution for the automotive would be the ability to successfully join these**components together with a resistance to corrosion and joint strength deterioration. Casting is the most economically**viable manufacturing route for both AI and Mg alloys. Recent advances in AI casting alloys and technology has**demonstrated the valid feasibility of enabling near net shaped casting of AI wrought alloys with its far superior**mechanical and performance properties to their casting alloy counterparts. This joint project initiative is to develop such**processes and technologies to enable prototyping of certain critical structural automotive components. Controlled**Diffusion Solidification (CDS), Ablation Casting and Semi Solid Processing using High Pressure Die Casting (HPDC)**process would be evaluated critically for three families of AI wrought alloys, namely, the 6xxx and 7xxx series of alloys.**The research team at Trento, Italy would be working on developing the 6xxx alloy series and the one in Canada would**be working on the 7xxx alloy series. Additionally, evaluating the casting of certain high performance Mg alloys in the**ablation casting process would also be carried out in this project along with potential alloy development to re-design**existing alloys to better suit the ablation casting process in order to maximize the properties and performance of the cast**components. An additional task in this project would be to develop and optimize a new dissimilar metal joining process,**in upset protrusion joining, based on a patent pending process to combine cast magnesium components with**themselves and with other AI and steel components. This initiative will include developing an optimum protrusion design**and optimum heating and forging processes to upset the protrusion and lock the two materials together.