Defect formation in light metal alloy castings

尽管铝合金铸件具有许多优点，但其容易产生大量与凝固有关的缺陷，包括宏观和微观空洞的形成以及氧化膜夹带，如果这些缺陷存在于结构件中，会导致疲劳和冲击性能降低。就车轮而言，这些缺陷也可能导致车轮表面的外观缺陷。本提案描述了一个战略项目，该项目在具有竞争力的制造和附加值产品和工艺领域，重点关注近净成形铸造工艺。本研究方案以铝合金近终形铸造过程中气孔和氧化膜的形成为研究对象，结合实验和最新的数值模拟技术。实验计划的目标是：1)改进对孔隙率和氧化膜缺陷形成的基本理解；以及2)提供适合于验证计划中开发的数值模型的数据。数值模拟的目的是：1)帮助设计实验程序并解释结果；2)提供工具供行业使用，以最大限度地减少这些关键缺陷的发生。该项目与加拿大丰田汽车公司和加拿大阿尔坎公司合作，将帮助培养3名博士生、1名应用科学硕士学生和1名博士后研究员。

Despite their many advantages, castings produced from aluminum alloys are prone to a number of solidification related defects include macro- and micro-void formation and oxide film entrainment, which if present in structural components can result in reduced fatigue and impact performance. In the case of wheels these defects can also result in cosmetic defects on the surface of the wheel.This proposal describes a Strategic Project in the area of Competitive Manufacturing and Value-Added Products and Processes with focus on Near-Net-Shape Casting Processes. This research proposal focuses on porosity and oxide film formation in aluminum alloy near-net shape casting and combines both experiments, and state-of-art numerical modeling. The experimental program will be aimed at: 1) generating an improved fundamental understanding of porosity and oxide film defect formation; and 2) providing data suitable for validation of the numerical models to be developed in the program. The numerical modeling will be aimed at: 1) helping to design the experimental program and interpret the results; and 2) provide tools for use by industry to minimize the occurrence of these critical defects. The program, run in partnership with Canadian Autoparts Toyota and Alcan, will contribute to the training of 3 Doctoral students, a Master of Applied Science student and a Post-Doctoral Fellow.