Development of a New Magnesium Alloy with Improved Ductility to Enable Joining via Self-Piercing Riveting (SPR)

子午线轻量化技术公司(MLT)是全球最大的轻质镁合金压铸供应商，为三大洲的大多数全球汽车制造商提供服务。为了开发新的镁合金应用，该组织迫切需要一种新的镁合金，这种合金可以通过自冲铆接(SPR)技术进行紧固。在汽车零部件中成功地用于连接其他金属的SPR，当镁位于紧固部件的下层时，出现了不成功和开裂的现象。MLT在他们的内部调查中发现，不同的镁合金在SPR过程中存在不同程度的裂纹，并相信适当设计的镁合金可以完全消除裂纹问题。新型镁合金应具有良好的SPR响应，并具有与AM50A镁合金相似的机械性能、腐蚀性能、铸造性能、可回收性和成本。在这个项目中产生的知识将使工业合作伙伴在开发新业务、创新和确保更高的市场份额方面具有竞争优势。在这个项目中培训的HQP将拥有轻量化运输应用方面的关键专业知识。他们将被定位为推动镁转化产业，并拥有在电子显微镜、X射线衍射、机械测试和计算材料工程方面的可移植技能。使用镁的轻量化将产生关键的环境效益。目前，运输部门的二氧化碳排放量占加拿大温室气体总排放量的25%，政府制定了到2050年将温室气体减少45%-65%的目标。车辆重量减少10%会带来6-8%的燃油经济性，这相当于(在汽车的整个生命周期内)每减少一公斤车辆重量就会减少17-20公斤的二氧化碳排放量。另一个关键好处是在加拿大创造价值。汽车制造商贡献了加拿大制造业国内生产总值(GDP)的12%，提供了超过55万个工作岗位。在MG汽车零部件行业创造专业知识和技术基础对加拿大的全球竞争非常重要，无论是为了维持目前的水平，还是为了使电动、燃料电池和混合动力汽车的未来技术能够创造新的就业机会和环境可持续性。

Meridian Lightweight Technologies (MLT) is the largest supplier of lightweight magnesium (Mg) die castingsin the world, serving most of the global automotive manufacturers on three continents. To develop a new Mgapplication, the organization urgently needs a new Mg alloy which can be fastened by Self-Piercing Riveting(SPR) technology. SPR, successfully used to join other metals in automotive components, shows lack ofsuccess and cracking when Mg is in the lower layer of fastening components. MLT, in their internalinvestigations has shown that different Mg alloys have different degree of cracking in the SPR process andbelieves a properly designed Mg alloy could completely eliminate the cracking issue. The new Mg alloy shouldhave good SPR response and offer mechanical, corrosion, casting performance, recyclability and cost similar tothe AM50A Mg alloy. The knowledge generated in this project will give the industrial partner a competitiveedge to develop new business, to innovate, and to secure higher market share. HQP trained in this project willhave key expertise in the lightweight transport applications. They will be positioned to advance the Mgtransformation industry and have transferable skills in electron microscopy, XRD, mechanical testing andcomputational materials engineering. The lightweighting using Mg will have key environmental benefits. CO2emissions from the transportation sector currently contribute 25% of Canada's total greenhouse gas emissions(GHGs) and the government has a target for reducing GHGs by 45-65% by 2050. 10% saving in vehicle weightleads to 6-8% fuel economy, which translates (during the life time of a car) to 17-20 kg reduced emissions ofCO2, per kg of vehicle weight reduced. Another key benefit is value creation in Canada. The automotivesector contributes 12% of Canada's manufacturing Gross Domestic Product (GDP) with more than 550,000jobs. Creating expertise and a technology-base in the Mg automotive parts industry is very important forCanada's global competition, both to sustain the current level and to enable future technologies of electric, fuelcell, and hybrid powered vehicles creating opportunities for new job creation, and environmental sustainability.