Evaluation and development of enabling technologies for lightweight automotive structural cast components with wrought aluminum and high performance magnesium alloys

该项目的动机是通过利用更多的AI和Mg来降低汽车的整体重量 用于底盘和车身结构部件的合金;从而减少燃料的使用和排放 对环境有害的二氧化碳气体。在汽车底盘和车身结构中引入AI和Mg将 需要合金的远为优异的上级机械性质和性能以超过严格的安全性 汽车结构部件的要求。现有的铝和镁铸造合金不符合这些安全性 在这些要求中，屈服强度超过300 MPa并且伸长率至少为10%是强制性的。一个关键 实现汽车轻量化多材料解决方案的一个特点是能够成功地将这些材料连接起来， 组件的耐腐蚀性和接头强度降低。铸造是最经济 铝合金和镁合金的可行制造路线。铝铸造合金和技术的最新进展 证明了近终形铸造铝变形合金的有效可行性，其具有远上级 机械和性能特性。这一联合项目倡议是为了开发这样的 工艺和技术，以实现某些关键结构性汽车部件的原型设计。控制 扩散凝固（CDS）、烧蚀铸造和使用高压压铸（HPDC）的半固态加工 对于三个系列的Al锻造合金，即6xxx和7 xxx系列合金，将对该工艺进行严格评估。 意大利特伦托的研究小组将致力于开发6xxx合金系列，加拿大的研究小组将 正在研究7 xxx合金系列。此外，评价某些高性能镁合金在铸造中的应用， 本项目还将沿着潜在的合金开发进行烧蚀铸造工艺，以重新设计 为了使铸件的性质和性能最大化 件.该项目的另一项任务是开发和优化一种新的异种金属连接工艺， 在镦粗突起连接中，基于待申请专利的方法将联合收割机铸造镁部件与 以及其他人工智能和钢铁组件。这一举措将包括开发一个最佳的突出设计 以及最佳的加热和锻造工艺，以镦粗突起并将两种材料锁定在一起。

The motivation for this project initiative is to reduce the overall weight of the automobile by utilizing more AI and Mg alloys for both the chassis and body structure components; thereby, leading to reduction in the use of fuel and emission of harmful C02 gas to the environment. The introduction of AI and Mg in the chassis and body structure of a car would necessitate far superior mechanical properties and performance of the alloys to surpass the stringent safety requirements for structural automotive components. The available AI and Mg casting alloys do not meet these safety requirements wherein an yield strength in excess of 300 MPa and an elongation of at least 1 0% is mandatory. A critical feature in achieving a light weight multi-material solution for the automotive would be the ability to successfully join these components together with a resistance to corrosion and joint strength deterioration. Casting is the most economically viable manufacturing route for both AI and Mg alloys. Recent advances in AI casting alloys and technology has demonstrated the valid feasibility of enabling near net shaped casting of AI wrought alloys with its far superior mechanical and performance properties to their casting alloy counterparts. This joint project initiative is to develop such processes and technologies to enable prototyping of certain critical structural automotive components. Controlled Diffusion Solidification (CDS), Ablation Casting and Semi Solid Processing using High Pressure Die Casting (HPDC) process would be evaluated critically for three families of AI wrought alloys, namely, the 6xxx and 7xxx series of alloys. The research team at Trento, Italy would be working on developing the 6xxx alloy series and the one in Canada would be working on the 7xxx alloy series. Additionally, evaluating the casting of certain high performance Mg alloys in the ablation casting process would also be carried out in this project along with potential alloy development to re-design existing alloys to better suit the ablation casting process in order to maximize the properties and performance of the cast components. An additional task in this project would be to develop and optimize a new dissimilar metal joining process, in upset protrusion joining, based on a patent pending process to combine cast magnesium components with themselves and with other AI and steel components. This initiative will include developing an optimum protrusion design and optimum heating and forging processes to upset the protrusion and lock the two materials together.