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

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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.