Through-process modelling: Casting for marine energy systems

贯通过程建模(TPM)是最近发展起来的一种材料工程设计方法，它可以通过考虑制造过程来提高部件的性能。在这种方法中，应用先进的建模工具，通过“虚拟”制造过程，以一个阶段的结果作为下一个阶段的输入，调查整个制造周期。TPM研究了热传递、应力发展、微观结构和缺陷形成的耦合模型，以预测制造部件的使用性能。拟议的NSERC-Strategic项目的目标是为铝铸造业创建一套TPM工具，以提高铸造质量和性能。潮汐清洁能源发电系统中的一个关键部件--将负荷从涡轮机叶片转移到发电机轴的集线器--将被用作演示部件。在潮汐涡轮机中使用铝合金铸件将确保达到部件性能目标。为了开发一套TPM工具包，以量化暴露在海洋环境中的铸件的微观结构、加工缺陷、腐蚀和疲劳，将采用一种独特的方法，包括数学建模、实验室测试和工业工厂试验。不列颠哥伦比亚省大学、法国国家高等技术学院、Canmetals、定制铝铸造厂、加拿大国防研究和发展公司以及由4家潮汐涡轮机公司(Mavi Innovation、New Energy Corp.、Alternative Hydro Solutions和Blue Energy)组成的财团已经建立了合作伙伴关系，以进行所需的研究。这一战略项目的结果将促进铝铸造行业的创新，特别是在高强度合金领域，这些领域受到与缺陷相关的高加工成本的困扰。这一战略项目还直接解决了与开发具有成本效益的

Through-Process Modelling (TPM) is a recently-developed materials engineering design approach that can be used to enhance component performance by taking the manufacturing process into consideration. In this approach, advanced modelling tools are applied to investigate, through a "virtual" fabrication process, the entire manufacturing cycle with the results of one stage used as input to the next. TPM studies couple models of heat transfer, stress development, microstructure, and defect formation in order to predict the in-service performance of a fabricated component. The objective of the proposed NSERC-Strategic Project is to create a TPM toolset for the aluminum foundry industry to improve casting quality and performance. A critical component in tidal-based clean energy-generating systems - the hub that transfers load from the turbine's blades to the shaft of the generator - will be used as a demonstration part. The use of aluminum alloy castings in tidal turbines will ensure component performance goals are reached. In order to develop a TPM toolset that quantifies microstructure, processing defects, corrosion, and fatigue in a cast component exposed to a marine environment, a unique methodology will be employed that includes mathematical modelling, laboratory testing, and industrial plant trials. A partnership between The University of British Columbia, France's Ecole Nationale Superieure de Mecanique et d'Aerotechnique, CanmetMaterials, Custom Aluminum Foundry, Defence Research and Development Canada, and a consortium of 4 tidal turbine companies (Mavi Innovations, New Energy Corp., Alternative Hydro Solutions, and Blue Energy) has been established to conduct the required research. The results of this Strategic Project will enable innovation within the aluminum foundry industry, especially in the area of high-strength alloys that are plagued by high processing costs related to defects. This Strategic Project also directly addresses fundamental challenges related to the development of cost-effective