Development of novel manufacturing route for automotive suspension parts

为了减轻汽车的重量和消耗，越来越多的汽车零部件采用轻质合金制造。铝铸件已用于动力总成，最近，作为板材和挤压在车身。悬架部件的应用也是一个新的趋势，因为铝在这些部件中的好处是减轻了重量，同时改善了道路处理和增加了噪音/振动阻尼。本项目的工业合作伙伴劳弗斯是一家采用铸造/挤压和锻造工艺制造的铝硅镁合金汽车悬架部件的供应商。制造路线的挤压和热处理部分允许生产细晶粒材料，但这是一个耗时/能量消耗的过程，成本高昂。为了提高成本效益并保持劳弗斯作为制造业领导者的战略地位，必须开发替代路线。在本项目中，将研究使用直接冷却（DC）铸棒取代传统铸造挤压/热处理步骤的可能性。由于这种铸造技术会产生不同的显微组织、晶粒组织和非均质性，因此必须对生产路线的每一步进行研究和优化，以提高所生产零件的最终疲劳性能。在这个项目中产生的知识将使工业合作伙伴在拥有具有成本效益的悬挂部件锻造工艺方面具有竞争优势，该技术将使他们能够开发新的业务，并进行创新以确保更高的市场份额。在这个项目中接受培训的HQP将拥有轻型运输应用（材料生产、挤压、制造、成型和应用）方面的关键专业知识，并将有助于将这些关键行业留在加拿大。

In order to reduce the weight and the consumption of car, more vehicle parts have been manufactured with lightweight alloys. Al castings have been used in the powertrain and, more recently, as sheet & extrusions in the car body. Applications in the suspension components is also a new trend as the benefit of Al in these components is the reduction in weight together with improved road handling and increased noise/vibration dampening. The industrial partner of the present projet, Raufoss, is a supplier of automotive suspension components in Al-Si-Mg alloy manufactured using a casting / extrusion and forging route. The extrusion and heat-treatment portion of the manufacturing route allow fine grained material to be produced, but it is a time/energy consuming process which is costly. In order to improve the cost effectiveness and maintain Raufoss strategic position as a manufacturing leader, alternate routes have to be developed. In the present project, the possibility of using a direct-chill (DC) cast rod to replace the conventional casting extrusion / heat treatment steps will be investigated. As different microstructures, grain structures, and heterogeneities will be generated with this castings technology, every step of the production route will have to be investigated and optimized to enhance the final properties of the produced parts in term of fatigue properties. The knowledge generated in this project will give the industrial partner a competitive edge in possessing a cost effective forging process for suspension components, the technology will enable them to develop new business, and to innovate to secure higher market share. HQP trained in this project will have key expertise in the lightweight transport applications (materials production, extrusion, fabrication, forming and applications) and will help keep these key industries in Canada.