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。考虑到这些目标，本研究计划有具体的研究目标：铝合金动力系统的高温性能，先进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和镁合金的创新增材铸造工艺。铝缸盖和发动机缸体需要高导热性来分配热负荷。这可以减轻有害的热应力积累，提高发动机效率，延长产品寿命。这项正在进行的研究需要使用瑞尔森大学，NRC-Chalk River（中子衍射）和以色列理工学院（HR-TEM和HR-SEM）的设施。凝固速度、化学改性和热处理将被适当地控制，以提高导热性，特别是通过控制硅改性。将研究几种动力总成合金，以开发工艺开发和转移到工业合作伙伴的迭代模型。该研究进一步寻求利用微纳米双峰增强和优化的超声辐照熔体来开发新的高强度镁基复合材料。在镁合金熔液中，超声辐照可以在较低的衰减下产生超细晶粒。分布颗粒的形貌、晶粒尺寸和二次相以及力学性能将被确定。超声参数和数据的科学分析将使工业合作伙伴能够开发高强度镁合金部件的工艺。石墨烯纳米薄片将通过球磨生产，并适当压实，作为铝合金的添加剂。将进行沉淀热处理、广泛表征、机械测试和热性能评估。轻质石墨烯铝基复合材料（AMC）将被开发，集成纳米晶体效应和由于石墨烯的添加而具有潜在的高导热性。将模型失蜡铸造与精密砂型增材打印的独特结合，开发出一种新型的蜂窝镁合金铸造工艺。低密度和高冲击合金可用于生产轻量化保险杠和汽车面板。该研究计划旨在通过高效的铝制动力总成组件来提高轻质材料的利用率；高强度镁复合材料；用于电动汽车电机和变速器的特殊铝复合材料和用于保险杠和车架的耐轻冲击镁合金。这将大大有助于减少排放和全球变暖，提高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.