A Novel Containerless Melting and Casting Process for Structural Cast Magnesium Alloys

该奖项的研究目标是开发一种生产高质量镁铸件的新技术。这项工作涉及先进的计算和实验方法，将导致新的电磁铸造工艺和工艺模型的发展，这足以适用于几种传统的电磁铸造和凝固工艺。研究方法将从建立熔炼操作的综合数学模型发展到了解铸造变量对铸造镁合金显微组织和力学性能的影响。交付成果包括建模和分析工具，加工-微观结构-属性数据库的开发，研究成果的文档和传播，工程学生教育以及本科生的工程研究经验。如果成功，这项研究的结果将提供一系列的计算工具，可用于优化金属的电磁熔化和铸造。该研究还将为生产高纯度、低缺陷含量和独特显微组织的铸件提供一种方法。例如，轻质镁合金反应性强，难以生产。本研究开发的计算工具将广泛适用于其他电磁熔炼和铸造技术，如颅骨感应熔炼和电磁铸造。研究结果将被传播，以允许制造精度更高、成本更低、重量更轻、可回收性更好的商业设备。研究生和本科生将受益于课堂教学和参与研究。来自阿拉巴马大学和传统黑人学院和大学的本科生将参与其中，为他们提供第一手的研究经验。

The research objective of this award is to develop a novel technology for producing high quality magnesium castings. The work involves advanced computational and experimental methods that will result in the development of a new electromagnetic casting process and of a process model that is general enough to apply to several conventional electromagnetic casting and solidification processes. The research approach will progress from the development of a comprehensive mathematical model of the melting operation to understanding of the influences of casting variables on the microstructures and mechanical properties of cast magnesium alloys. Deliverables include a modeling and analysis tools, development of a processing-microstructure-properties database, documentation and dissemination of research results, engineering student education, and engineering research experiences for undergraduates.If successful, the results of this research will provide a series of computational tools that can be used to optimize electromagnetic melting and casting of metals. This research will also yield a means to produce castings with high purities, low defect contents, and unique microstructures. Examples include light weight magnesium alloys which are highly reactive and difficult to produce. The computational tools developed in this research will be broadly applicable to other electromagnetic melting and casting techniques such as skull induction melting and electromagnetic casting. The results will be disseminated to allow the creation of commercial devices that have increased precision, reduced cost, reduced weight, and improved recyclability. Graduate and undergraduate engineering students will benefit through classroom instruction and involvement in the research. Undergraduate students from the University of Alabama and historically black colleges and universities will be engaged to provide them firsthand research experience.