Phenomenological Studies of Light alloys for Enhanced Efficiency, Performance and Strength of Automotive Powertrain Components for Next Generation Vehicles

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The global quest for next generation electric vehicles, reduced fossil fuel use and reduced emissions have spurred the development of lightweight and energy efficient automotive vehicles. With these goals in view, this research proposal has specific objectives to investigate: high temperature performance of aluminum alloy powertrain systems, novel methods for advanced high strength magnesium metal matrix composites, aluminum graphene matrix composites for electric vehicles and innovative additive casting processes for magnesium alloys. High thermal conductivity of aluminum cylinder heads and engine blocks is required to distribute heat loads. This can mitigate detrimental thermal stress accumulation, improving engine efficiency and extending product life. This ongoing study entails use of the facilities at Ryerson University, NRC-Chalk River (neutron diffraction) and Technion, Israel (HR-TEM and HR-SEM). Solidification rate, chemical modification and heat treatment will be suitably manipulated to improve thermal conductivity, particularly through manipulation of silicon modification. Several powertrain alloys will be investigated with a view to developing an iterative model for process development and transfer to the industrial partner. The proposed research further seeks to develop new high strength magnesium matrix composites using micro- and nano-bimodal reinforcements and optimized ultrasonic irradiation of the melt. Ultrasonic irradiation in the molten magnesium alloy can be effective at relatively low attenuation resulting in ultrafine grain. The morphology of the distributed particles, grain size and secondary phases, and the mechanical properties will be determined. The sonication parameters and scientific analysis of data will enable process development for high strength Mg alloy components for the industrial partner. Graphene nano-platelets will be produced by ball-milling and suitably compacted as an addition for aluminum alloy. Precipitation heat treatment, extensive characterization, mechanical testing and evaluation of thermal properties will be carried out. Lightweight graphene Al matrix composites (AMC) will be developed, integrating nanocrystalline effects with potential high thermal conductivity due to graphene additions. A novel casting process for cellular magnesium alloy will be developed through unique combination of lost wax casting of patterns and additive printing of precision sand molds. Low density and high impact alloy can be used to produce lightweight bumpers and auto panels. The research proposal seeks to enhance the utilization of lightweight materials through high-efficiency aluminum powertrain components; high-strength magnesium composites; special aluminum composites for electric vehicle motors and transmission and light impact-resistant Mg alloys for bumpers and frames. These will significantly contribute to reducing emissions and global warming, and improving the quality of life for the human society.