Engineered 3D Microstructures for Automotive Aluminum Extrusions

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In this proposal, we will address the need to engineer the microstructure of advanced automotive aluminium alloys to improve the energy efficiency of vehicles (e.g. increasing electric vehicle range and decreasing fuel consumption). This will be accomplished through a partnership between an established team of researchers from The University of British Columbia and Rio Tinto Aluminium. In particular, we will develop understanding of the underlying physical mechanisms that control fracture in energy absorption applications, e.g. in crash situations. We will use an experimental approach to systematically explore the effects of grain size/shape, crystallographic texture and second phase particles on the directional dependence of fracture properties using a careful experimental matrix of alloys with known processing histories. The proposal will take advantage of state-of-the-art characterization techniques currently being acquired and developed at UBC. These will allow: (1) unprecedented 3D characterization of microstructure (with the new Xe focused ion beam/electron microscope) (2) local strain measurements with high resolution digital image correlation and (2) testing of samples in the microscope for direct observation on the sequence of fracture events. Our results will inform simulations and guide alloy design via (1) new knowledge on the fundamental mechanisms which control fracture and ductility of advanced aluminum extrusion alloys which will be published in the scientific literature, (2) the training and education of 3 PhD students, 2 Masters students, 3 postdoctoral fellows and 1 research engineer in a field of critical importance to Canada and iii) the transfer of knowledge to our industry partner, Rio Tinto Aluminium who will commercialize results for the Canadian and global market.