Exploitable results
Light materials are of importance for the construction and use of components in transport industry. The project is focussed on light metals, on the thixoforming process, which is near-net-shape, and on complex small car components with a potential weight reduction of 50%.
The materials selected are several Al-alloys, one Al-metal matrix composite with ceramic SiC particles, and one Mg-alloy.
The materials are characterized with respect to microstructure, in particular grain-shape. The rheological behaviour for the semi-solid-state is analyzed and characterized. The structure and rheology form the basis for the thixoforming processes.
The reheating technology, the analysis and design of dies, and experiments to establish thixoforming procedures were performed for the various materials. A good microstructure with globular grains was a prerequisite for a successful processing of components. The Al-based materials were in general good, while the relatively new Mg-alloy needs further development. The analysis and re-design of components and design of dies was performed by FEM-modelling.
The thixoformed samples and components were characterized by non-destructive methods, by microstructural analysis and by mechanical testing. The quality of the components was, in general, more controlled by the geometry than by the materials.
A total of five car components were identified as candidates for development. Four were selected, (re-) designed, manufactured and tested under simulated service conditions. The four components were:
- rear axle support, in Al and Mg;
- brake drum, in Al-MMC;
- engine bracket, in Mg;
- suspension arm, in Mg.
The components were of moderate to good quality; the service performance was acceptable, but needs development for the new materials Al-MMC and Mg.
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