Design and Optimization of Joining shaped casting of Al 7xxx structural alloy component using Self Piercing Rivets

自2012年以来，该研究团队和赞助商一直在进行持续的研发活动，以开发，测试和实施新的和改进的铝合金，用于使用高真空高压压铸（HVHPDC）工艺制造结构汽车铸件部件。与传统的Al- si - mg合金（如Silafont、mercaly、Aural和Castasil）相比，一种新的Al 7xxx合金（Al- zn - mg）家族已经成功开发出来，使用HVHPDC工艺，并通过优化热处理工艺进一步改善了性能和性能，从而提高了机械性能和工艺性能。此外，合金的开发显著提高了模具的使用寿命，从而降低了昂贵的生产维护成本。该合金已在北美和欧洲的工业生产试验中得到验证，用于制造汽车结构铸件，如侧面碰撞门梁，冲击塔和顶帽。该研发计划的首要目标是开发新的铝合金系列，从而实现汽车结构部件的显著轻量化，为OEM和客户带来经济优势，并带来环境效益，如减少运行中燃料使用所产生的温室气体（GHG）的减少。目前的项目旨在通过开发优化的铆接连接技术来进一步推进研发工作，从而以最低的成本和能源消耗将这些结构铸件集成到汽车上层结构中。铆接是航空航天和汽车工业中常用的连接结构部件的方法，它提供了一种可行的加工路线，故障风险最小。用新开发的合金铆接汽车结构件铸件的初步探索性研究令人鼓舞，并减轻了这种铸造技术成功商业化的风险，同时具有经济和环境效益。接头和铸件的剥落和应力腐蚀行为也将被评估和量化。

Since the year 2012, there has been a continual R&D activity by this research team and sponsor to develop, test and implement new and improved aluminium alloys for manufacturing structural automotive cast components using the high vacuum high pressure die casting (HVHPDC) process. A new family of Al 7xxx alloys (Al-Zn-Mg) has been successfully developed to yield shaped castings with improved mechanical properties and process performance using the HVHPDC process along with further improvements to properties and performance through optimized heat treatment processes, compared to the conventional Al-Si-Mg family, such as Silafont, Mercaloy, Aural and Castasil. Additionally, the alloys were developed to significantly improve the life of the die tool, thus reducing the expensive maintenance cost of production. The alloys has been validated by industrial production trials in North America and Europe for manufacturing structural automotive castings such as the side impact door beam, shocktower and tophat. The overarching aim of this R&D program is to develop new families of Al alloys that would lead to significant lightweighting of automotive structural components to bring economic advantages to the OEM and customers in addition to environmental benefits such as reduction in green house gases (GHG) from reduced fuel use in operation. The current project aims to further the R&D efforts by developing optimized joining technology in riveting, to enable integration of these structural castings into an automobile superstructure with minimum cost and energy use. Riveting is popular method of joining structural components in both aerospace and automotive industries and offers a viable processing route with the least risk of failure. Preliminary exploratory studies of riveting the structural automotive components cast with the newly developed alloys have been encouraging and alleviated the risk in successful commercialization of this casting technology with the economical and environmental benefits. Exfoliation and Stress Corrosion behaviour of the joints and castings will also be evaluated and quantified.