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

全球对下一代电动汽车的追求，减少化石燃料的使用和减少排放，刺激了轻量化和节能汽车的发展。有鉴于此，本研究计划有明确的目标进行研究：铝合金动力总成系统的高温性能、先进的高强度镁金属基复合材料的新方法、电动汽车用铝石墨烯基复合材料以及镁合金的创新添加剂铸造工艺。铝制气缸盖和发动机机体需要较高的导热系数来分配热负荷。这可以减少有害的热应力积累，提高发动机效率和延长产品寿命。这项正在进行的研究需要使用赖尔森大学、NRC-Chalk River(中子衍射)和以色列Technion的设施(HR-TEM和HR-SEM)。适当地控制凝固速度、化学变质和热处理以提高导热系数，特别是通过操纵硅改性。将对几种动力总成合金进行研究，以期开发一种迭代模型，用于工艺开发和向工业伙伴转移。建议的研究进一步寻求利用微米和纳米双峰增强材料和优化的熔体超声辐照来开发新的高强度镁基复合材料。超声辐照在镁合金熔体中可以在相对较低的衰减下有效地产生超细晶。将测定分布颗粒的形态、晶粒度和第二相，以及力学性能。超声波参数和对数据的科学分析将使工业伙伴能够开发高强度镁合金部件的工艺。采用球磨法制备了石墨烯纳米片，并将其作为铝合金添加剂进行了适当的压制。将进行沉淀热处理、广泛的表征、力学测试和热性能评估。轻质石墨烯铝基复合材料(AMC)将结合纳米晶效应和石墨烯添加可能带来的高导热系数。将模样消失蜡铸造与精密砂型印刷相结合，开发出一种新颖的蜂窝镁合金铸造工艺。低密度、高冲击合金可用于生产轻型保险杠和汽车覆盖件。该研究提案旨在通过高效铝动力总成部件、高强度镁复合材料、电动汽车发动机和变速器的特殊铝复合材料以及保险杠和车架的轻抗冲击镁合金来提高轻质材料的利用率。这些都将大大有助于减少排放和全球变暖，并改善人类社会的生活质量。

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.