Through-process modelling: Casting for marine energy systems

全过程建模（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，通过“虚拟”制造过程，应用先进的建模工具来研究整个制造周期，其中一个阶段的结果用作下一个阶段的输入。TPM研究传热、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。提议的nserc战略项目的目标是为铝铸造行业创建一个TPM工具集，以提高铸件的质量和性能。潮汐清洁能源发电系统的一个关键部件——将负荷从涡轮机叶片转移到发电机轴上的轮毂——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。为了开发一个TPM工具集，量化暴露在海洋环境中的铸造部件的微观结构、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。英属哥伦比亚大学、法国国立高等机械与航空技术学院、CanmetMaterials、定制铝铸造厂、加拿大国防研究与发展部以及由4家潮汐涡轮机公司（Mavi Innovations、新能源公司、替代水电解决方案和蓝色能源）组成的联盟已经建立了合作伙伴关系，以进行所需的研究。这一战略项目的成果将推动铝铸造行业的创新，特别是在高强度合金领域，该领域受到与缺陷相关的高加工成本的困扰。该战略项目还直接解决了与成本效益发展有关的基本挑战

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 tidal energy systems, and thus represents an opportunity for Canada to promote the use of aluminum alloy castings, an industrial base in which the country has great expertise, to the clean energy sector.