New Generation of Castable Al Alloys Possessing High Strength and Elevated Electrical Conductivity

对具有高导电性的高强度可铸造铝基合金的需求不断增加。这些铝合金的主要应用之一是制造电动汽车（EV）部件。这些部件通常通过高压压铸（HPDC）工艺制造，这需要高的耐热撕裂性。因此，除了高屈服强度和改善的电导率（EC）之外，还需要良好的可铸性。然而，开发这种新的铝合金是相当具有挑战性的，因为上述要求是矛盾的因素。因此，需要一个全面和系统的研究计划，以开发高强度铝基合金，表现出高EC与足够的可铸造性。本研究计划的三个主要短期目标是：1）利用热力学模型和实验数据的系统集成，开发纳米析出物/弥散相强化的铸造铝导体：2）研究热处理参数对纳米析出物/弥散相形成的影响; 3）开发由Al 2 O3纳米颗粒（nanop）增强的高强度可浇铸铝基复合材料导体，并进行中试HPD制造试验。将考虑含有各种Si、Mg、Fe、Ce和Zr含量的Al-Ni基合金。采用热力学模型模拟合金元素对凝固路径、微观组织演变和热裂敏感性的影响。通过实验研究了这些有前途的合金的铸造性能、力学性能和电导率。将开发一种创新的热处理工艺来促进纳米结构的沉淀物/弥散体。将进行先进的微观结构表征，以研究沉淀物/弥散体的形成动力学。将开发一个属性模型，以确定潜在的强化因素对强度和EC的贡献。此外，还将探索由Al 2 O3纳米颗粒（nanop）增强的Al基复合材料导体。在铝熔体中通过铝热反应合成NiO颗粒，促进Al基体中的Al 2 O3纳米颗粒。还将进行HPDC生产试验，以验证开发产品的加工性能和性能。该ND计划的长期目标与Al行业的优先事项相一致，是建立一个包容性和多样化的研究小组，能够应对与Al转型相关的实际和根本挑战。在未来5年内，这些长期研究目标的实现将为未来的项目奠定基础。该计划还将为5名在就业市场上具有竞争力的HQP提供多学科培训。该计划还将鼓励许多富有成效的国家和国际合作，并有助于铝产品和工艺开发的科学改进。

The demand for high strength castable Al-based alloys possessing high conductivity is continuously increasing. One of the main applications of these Al alloys is on fabrication of electric vehicle (EV) components. These components are usually made through high pressure die-casting (HPDC) process, which requires high hot tearing resistance. Hence, in addition to high yield strength and improved electrical conductivity (EC), good castability is also required. However, developing such a new Al alloy is quite challenging, as the abovementioned requirements are contradicting factors. Therefore, a comprehensive and systematic research plan is required to develop high strength Al-based alloys exhibiting high EC with sufficient castability. Three principal short term objectives of the current research program are to: 1) Develop castable Al conductors strengthened by nanosized precipitates/dispersoids using a systematic integration of thermodynamic models and experimental data; 2) Investigate the influence of heat-treatment parameters on the formation of nanosized precipitates/dispersoids; 3) Develop high-strength castable aluminum matrix composites conductors reinforced by Al2O3 nanoparticles (nanop) and conduct pilot HPDC-manufacturing trials. Al-Ni-based alloys containing various Si, Mg, Fe, Ce and Zr contents will be considered. Thermodynamic modeling will be employed to simulate the impact of the alloying elements on solidification path, microstructure evolution, and hot tearing susceptibility. The castability, mechanical properties and EC of the promising alloys will be investigated by experimental trials. An innovative heat treatment process will be developed to promote the nanostructured precipitates/dispersoids. Advanced microstructure characterisation will be conducted to study the formation kinetics of the precipitates/dispersoids. A property model will be developed to identify the contribution of underlying strengthening factors on strength and EC. Furthermore, Al matrix composites conductors reinforced by Al2O3 nanoparticles (nanop) will also be explored. The Al melt will be synthesized by NiO particles, to promote Al2O3 nanop in Al matrix through an aluminothermy reaction. A pilot manufacturing HPDC trials will also be conducted to validate the developed products' processability and performance. The long-term objective of this ND program, aligned with the Al industry's priorities, is to establish an inclusive and diverse research group capable of answering the practical and fundamental challenges related to Al transformation. Over the next 5 years, achievement of these long-term research goals will provide the foundation for future projects. This program will also provide multidisciplinary training for 5 HQPs who will be competitive in the job market. The program will also encourage many fruitful national and international collaborations, and contribute to the evolution of science-based improvements in Al products and process development.