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

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。

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.