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

锻铝和高性能镁合金轻量化汽车结构铸造部件使能技术的评估和开发

• 批准号: 435504-2012
• 负责人: Shankar, Sumanth
• 金额: $ 45.09万
• 依托单位: McMaster University
• 依托单位国家: 加拿大
• 项目类别: Automotive Partnership Canada Project
• 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=664868
• 关键词: Evaluation; development; enabling; technologies; lightweight

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.

该项目倡议的动机是通过在底盘和车身结构部件上使用更多的AI和镁**合金来减轻汽车的整体重量；从而减少燃料的使用和向环境排放有害的二氧化碳气体。在汽车底盘和车身结构中引入AI和镁，将**需要合金具有更高的机械性能和性能，以超过汽车结构部件的严格安全**要求。可用的铝和镁铸造合金不符合这些安全**要求，其中屈服强度超过300兆帕和至少10%的伸长率是强制性的。实现汽车用轻质多材料解决方案的一个关键**特征是能够成功地将这些**组件连接在一起，并具有耐腐蚀和抗连接强度恶化的能力。铸造是铝和镁合金最经济、最可行的生产路线。AI铸造合金和技术的最新进展**证明了AI锻造合金以其远优于铸造合金的机械和性能**实现近净成形铸造的有效可行性。该联合项目计划旨在开发此类**工艺和技术，以实现某些关键结构汽车部件的原型制作。**可控扩散凝固(CDS)、烧蚀铸造和使用高压压铸(HPDC)的半固态加工**将对三个系列的AI锻造合金进行严格的评估，即6xxx和7xxx系列合金。**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7xxx合金系列的研究。此外，该项目还将评估某些高性能镁合金在**烧蚀铸造过程中的铸造情况，以及潜在的合金开发，以重新设计**现有合金以更好地适应烧蚀铸造过程，以便最大限度地提高铸造组件的性能和性能。该项目的另一项任务将是开发和优化一种新的异种金属连接工艺，基于一种正在申请专利的工艺，将铸造镁部件与**自身以及与其他AI和钢铁部件相结合。这一倡议将包括开发最佳的凸起设计**和最佳的加热和锻造工艺，以使凸起加厚并将两种材料锁定在一起。