Objectif
1. Selection and composition of test specimens and generic component: Continuous alumina fibres were chosen for the reinforcement of Al-alloys, whereas high strength and high modulus C-fibres for Mg-alloys. The alloy AZ91 was selected for the embedding casting. Hybrid samples for shear testing and generic components in the shape of a ring, a flared housing part and a housing hub were designed.
2. Macro- and micro-mechanical investigation of stress distributions: The internal stresses in the different MMC systems were modelled taking into account the ring shape and the macro-interface between MMC insert and unreinforced casting. Thermally induced stresses as well as external loads were considered for these anisotropic materials.
3. Preform design and manufacturing: Preforms of continuous fibres were wound, woven, braided or composed by fabrics. Ceramic short fibres were investigated aiming for compatibility with Mg-melt.
4. MMC-insert processing: The melt infiltration by pressure assisted investment casting, gas pressure infiltration, direct and indirect squeeze casting was adapted to produce the reinforcing inserts with Al and Mg matrix.
5. Shape and surface conditioning of MMC-inserts: Zn- and Sn-rich coatings on the Al-MMC inserts were tested to provide metallurgical bonding with the Mg casting. On the other hand protective anodizing was tried. The macro-interface was investigated with respect to geometry and unreinforced surface layers on the inserts.
6. Adaptation of Mg casting techniques to hybrid production: The hybrid test samples were produced by pressure die casting, indirect and direct squeeze casting. Gas pressure infiltration was scaled up for the one step Mg-hybrid processing technique. The feasibility of Mg investment casting was studied.
7. Material characterisation of inserts and hybrid parts: The developed MMC samples were tested with respect to stiffness, strength, shear properties, fatigue and thermal expansion. The hybrids' shear properties, corrosion resistance and internal stresses were investigated. Non-destructive testing methods (ultrasonics, X-ray transmission and computer tomography) were adapted to assess the developed hybrid samples.
8. Evaluation of the economic and ecological aspects: The costs of material, equipment and labour were collected and compared with the possible weight savings of up to 30% and the deduced ecological impact. The feasibility of series production was estimated.
BE95-1183 Design and Processing of Selectively Reinforced Mg-based Components
The project's target is to provide material technologies to substitute even aluminium components for aeronautical and automotive applications by lighter castings based on magnesium, which is selectively reinforced to comply with the service requirements: high strength and stiffness, fatigue, creep and corrosion resistance at low weight. A weight saving potential of 30% with respect to an equivalent aluminium part seems achievable. Although the optimistic expectations of recent years in the economic impact of metal matrix composites (MMC) could not be realized, the technical potential still exists to increase the weight-specific properties of light metals many times. It can be exploited by economical usage of the expensive reinforcement and by appropriate processing techniques, which require a scientific background. Therefore the objectives of the project are:
- To develop economic-production techniques for selectively reinforced light metal hybrid components consisting of a minimum amount of reinforcement by MMC, taking advantage of a two-step production route, where in a 1st step the continuous fibre reinforced MMC-insert is designed and processed at its optimum strength, which in a 2nd step is embedded into a highstrength Mg-based casting produced by modified conventional foundry techniques. A single-step technique to generate selectively reinforced Mg-parts will be investigated for comparison.
- To provide criteria for the selection and the design of such hybrid components tailored to meet the service requirements. Material research and micromechanical modelling form the basis for that development and are supplemented by specially adapted thermo-mechanical testing.
- To offer alternative process techniques together with their pros and cons for the production of small and medium/large series components demonstrated by the fabrication and evaluation of` prototype components. The investigation of bonding strength and internal stresses due to the partial reinforcement requires a major research effort to achieve sufficient load transfer capability.
The weight savings of highly accelerated and/or dynamically stable net shape parts made of selectively reinforced magnesium open the chance for the redesign of the corresponding system inducing further weight reductions, which will be necessary to achieve a significant increase in fuel efficiency of vehicles, which is required to reduce atmospheric pollution.
Champ scientifique (EuroSciVoc)
CORDIS classe les projets avec EuroSciVoc, une taxonomie multilingue des domaines scientifiques, grâce à un processus semi-automatique basé sur des techniques TLN. Voir: Le vocabulaire scientifique européen.
CORDIS classe les projets avec EuroSciVoc, une taxonomie multilingue des domaines scientifiques, grâce à un processus semi-automatique basé sur des techniques TLN. Voir: Le vocabulaire scientifique européen.
- ingénierie et technologie ingénierie des materiaux composites
- sciences naturelles sciences chimiques chimie inorganique métal alcalinoterreux
- sciences naturelles sciences chimiques chimie inorganique métal pauvre
- ingénierie et technologie ingénierie des materiaux revêtement et films
- ingénierie et technologie génie de l'environnement énergie et combustibles
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5282 Ranshofen
Autriche
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