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持续开展研发活动，开发、测试和实施新型和改进的铝合金，用于使用高真空高压压铸 (HVHPDC) 工艺制造结构汽车铸造部件。 已成功开发出新的 Al 7xxx 合金系列 (Al-Zn-Mg)，可使用 HVHPDC 工艺生产具有改进的机械性能和工艺性能的成型铸件，并通过优化的热处理工艺进一步改进性能和性能。传统的 Al-Si-Mg 系列，例如 Silafont、Mercaloy、Aural 和 Castasil。 此外，开发这些合金的目的是显着提高模具的使用寿命，从而降低昂贵的生产维护成本。 该合金已通过北美和欧洲的工业生产试验的验证，可用于制造汽车结构铸件，例如侧面防撞门梁、减震塔和顶帽。 该研发计划的总体目标是开发新的铝合金系列，从而显着减轻汽车结构部件的重量，除了减少温室气体（GHG）排放等环境效益外，还为原始设备制造商和客户带来经济优势。减少运行中的燃料使用。 当前项目旨在通过开发优化的铆接连接技术来进一步推进研发工作，从而以最低的成本和能源消耗将这些结构铸件集成到汽车上部结构中。 铆接是航空航天和汽车行业连接结构部件的常用方法，提供了一种可行的加工路线，且故障风险最小。 用新开发的合金铸造的汽车结构部件的铆接初步探索性研究令人鼓舞，并降低了该铸造技术成功商业化的风险，具有经济和环境效益。 接头和铸件的剥落和应力腐蚀行为也将被评估和量化。