Design and Optimization of Joining shaped casting of Al 7xxx structural alloy component using Self Piercing Rivets

Al 7xxx结构合金构件自冲铆钉连接成形铸件的设计与优化

• 批准号: 543964-2019
• 负责人: Shankar, Sumanth
• 金额: $ 3.93万
• 依托单位: McMaster University
• 依托单位国家: 加拿大
• 项目类别: Collaborative Research and Development Grants
• 财政年份: 2019
• 资助国家: 加拿大
• 起止时间: 2019-01-01 至 2020-12-31
• 项目状态: 已结题
• 来源: https://www.nserc-crsng.gc.ca/ase-oro/Details-Detailles_eng.asp?id=690425
• 关键词: Design; Optimization; Joining; shaped; casting

Since the year 2012, there has been a continual R&D activity by this research team and sponsor to develop, test and implement new and improved aluminium alloys for manufacturing structural automotive cast components using the high vacuum high pressure die casting (HVHPDC) process. A new family of Al 7xxx alloys (Al-Zn-Mg) has been successfully developed to yield shaped castings with improved mechanical properties and process performance using the HVHPDC process along with further improvements to properties and performance through optimized heat treatment processes, compared to the conventional Al-Si-Mg family, such as Silafont, Mercaloy, Aural and Castasil. Additionally, the alloys were developed to significantly improve the life of the die tool, thus reducing the expensive maintenance cost of production. The alloys has been validated by industrial production trials in North America and Europe for manufacturing structural automotive castings such as the side impact door beam, shocktower and tophat. The overarching aim of this R&D program is to develop new families of Al alloys that would lead to significant lightweighting of automotive structural components to bring economic advantages to the OEM and customers in addition to environmental benefits such as reduction in green house gases (GHG) from reduced fuel use in operation. The current project aims to further the R&D efforts by developing optimized joining technology in riveting, to enable integration of these structural castings into an automobile superstructure with minimum cost and energy use. Riveting is popular method of joining structural components in both aerospace and automotive industries and offers a viable processing route with the least risk of failure. Preliminary exploratory studies of riveting the structural automotive components cast with the newly developed alloys have been encouraging and alleviated the risk in successful commercialization of this casting technology with the economical and environmental benefits. Exfoliation and Stress Corrosion behaviour of the joints and castings will also be evaluated and quantified.

自2012年以来，该研究团队和赞助商进行了不断的研发活动，以使用高真空高压铸件（HVHPDC）流程来开发，测试和实施新的和改进的铝合金，以制造结构性汽车铸件。 与常规的AL-SI-MG家族（例如Silafont，Mercaloy，Mercaloy，Mercaloy，Aural and Mercaloy and Mercaloy and Mercaloy and Mercaloy and Mercaloy and Mercaloy and aural and aural and aural and aural and aural and aural and a a al-Zn-mg），已成功开发了一个新的AL 7XXX合金（Al-ZN-MG），以改善机械性能和过程性能，并进一步改善特性和性能，以进一步改善特性和性能，例如Silafont，Mercaloy，Mercaloy，Mercaloy，Aural和Castasil。 此外，合金的开发是为了显着改善模具工具的寿命，从而降低了昂贵的生产成本。 这些合金已通过北美和欧洲的工业生产试验进行了验证，用于制造结构性汽车铸件，例如侧面影响门梁，冲击式和Tophat。 该研发计划的总体目的是开发新的AL合金家族，这些家族将导致汽车结构组件的大量轻巧，除了降低燃料燃料的燃料使用量减少绿色房屋气体（GHG）之外，还可以为OEM和客户带来经济优势。 当前的项目旨在通过开发优化的连接技术来进一步促进研发工作，以使这些结构性铸件以最低的成本和能源使用的速度将这些结构性铸件集成到汽车上层建筑中。 铆接是在航空航天和汽车行业中连接结构组件的流行方法，并提供了一条可行的处理途径，失败风险最小。 关于用新开发的合金铸造的结构性汽车组件铆接的初步探索性研究令人鼓舞，并减轻了这种铸造技术成功商业化的风险，并具有经济和环境的好处。 关节和铸件的去角质和应力腐蚀行为也将进行评估和量化。