Shrinkage-related Casting Defects in Light Metal Alloys

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The demand for new or improved light metals components in the automotive and aerospace industries continues to be driven by the need for improved fuel economy and performance through weight savings. Cast aluminum alloy products have shown good market penetration by replacing ferrous-based components in automotive engines and through part consolidation in suspension components. While light metals usage may advance vehicle energy efficiency, continuous improvement is needed in the upstream processes to enhance product quality and increase yield and production energy efficiency. The improvement of shape casting processes through the reduction of shrinkage-related casting defects has been selected for consideration in this NSERC Discovery Grant. The proposed research program is focused on developing new and fundamental knowledge related to the susceptibility of model (binary) and commercial alloys to form three casting defects: i) macrosegregation, ii) macroporosity, and iii) surface depressions. All three of these defects are intimately related to shrinkage-related liquid metal feeding during solidification. A combined approach involving experimental castings and mathematical modeling is proposed to generate necessary knowledge and to develop computational tools to quantify the susceptibility of metallic alloys to form defects related to shrinkage-based liquid metal feeding. Canada enjoys a competitive advantage in metal casting technology, including primary and secondary (shape casting) casting processes, developed through experience and sustained research. The continued development of new knowledge relevant to the casting industry is critical to maintaining this competitive advantage. Developing a more fundamental understanding of shrinkage-related liquid metal feeding defects and developing tools to quantitatively predict their formation will ultimately lead to better castings and more efficient casting processes. This will enable Canadian manufacturing companies to remain competitive while facing increasing pressure from off-shore manufactures.