Castable and conductive light metal alloys for next-generation automotive powertrain applications

未来十年，汽车业的变化将超过过去100年的总和。快速而显著的气候变化推动了低成本、高效率、不影响安全性的汽车的发展。应对这些挑战的新技术包括1)采用先进材料的轻量化和2)动力总成电气化(混合动力、电池和燃料电池)以提高效率。混合动力、电池电动和燃料电池动力系统包括电池托盘、电机和逆变器外壳、导体板、电池冷却系统和车载电子外壳。这些部件和其他部件一样，必须快速吸收和散热(即具有高导热性)，以便有效地运行车辆，同时仍具有重量轻、价格低廉和易于制造的特点。*传统的铝和镁合金具有汽车应用所需的强度/重量比。然而，现有的合金是为基于燃烧的汽车动力总成开发的，在仍易于制造下一代混合动力、电动和燃料电池动力总成的同时，还不具备所需的高导热系数。*本研究计划的目标是研究非传统合金的添加和复合增强，以生产新型浇注料、高导热系数的铝和镁合金。我们将通过凝固分析、深入的微结构表征、力学测试和浇注性评估(热裂、流动性和收缩)来研究微观结构、加工和导热系数之间的关系。该研究建立在申请者在汽车和航空航天领域的轻合金(铝和镁)的凝固和加工方面的工业和学术经验的基础上。拟议研究的成功完成将为HQP提供一个独特和丰富的培训环境，他们将接触到最先进的实验方法、知识收集和软技能，这些将直接应用于学术界和工业界的职业生涯。*这项重大研究将进一步了解下一代汽车动力总成所需的高导热铝合金和镁合金的成分和铸造。加拿大将从这项研究中看到实质性和立竿见影的好处，并保持其世界级汽车经济体的地位。此外，这项研究将通过促进可持续交通部门的下一代动力总成来帮助加拿大实现其排放目标。

The automotive industry will change more in the next ten years than in the last 100 years combined. Rapid and significant climate change has motivated the development of low-cost, efficient automotive vehicles without compromising safety. New technologies to meet these challenges include 1) lightweighting with advanced materials and 2) powertrain electrification (hybrid, battery electric and fuel cells) to improve efficiency. Hybrid, battery electric and fuel cell powertrains contain battery trays, motor and inverter casings, conductor plates, battery cooling systems and in-car electronic casings to operate. These components as well as others must quickly absorb and dissipate heat (i.e. have high thermal conductivity) for efficient vehicle operation while still being lightweight, inexpensive and easy to manufacture. ******Conventional aluminum and magnesium alloys have the required strength/weight ratios for automotive applications. However, existing alloys were developed for combustion based automotive powertrains and do not have the requisite high thermal conductivity while still being easy to manufacture that next-generation hybrid, electric and fuel cell powertrains demand.******The objective of this research program is to investigate non-traditional alloy additions and composite reinforcements to produce novel castable, high thermal conductivity aluminum and magnesium alloys. We will examine the relationships between microstructure, processing and thermal conductivity using solidification analysis, in depth microstructure characterization, mechanical testing and castability evaluation (hot tearing, fluidity and shrinkage). The research builds upon the applicants' industrial and academic experience in solidification and processing of light alloys (aluminum and magnesium) for the automotive and aerospace sectors. Successful completion of the proposed research will offer a unique and enriching training environment for HQP, who will be exposed to state-of-the-art experimental methods, knowledge gathering and soft skills that will be directly transferable to careers in academia and industry.******This significant research will further the understanding of composition and casting for high thermal conductivity aluminum and magnesium alloys necessary for next-generation automotive powertrains. Canada will see substantial and immediate benefits from this research and sustain its position as a world class automotive economy. In addition, the research will help Canada reach its emission targets by promoting next-generation powertrains for a sustainable transportation sector.