Grant: Strategic Projects - Group

Within the Canadian automotive sector there exists an unwavering need to manufacture high volumes of light weight, complex parts in an economical manner. Aluminum Powder Metallurgy (PM) is acknowledged as a new means by which this can be realized and now represents a rapidly expanding market in many countries. Unfortunately, there is effectively no Canadian presence in the commercial application of this technology. Hence, as opportunistic nations continue to capitalize Canada merely falls further behind. To help alleviate this deficiency, this proposal strategically unites academics with a leading PM parts manufacturer (GKN Sinter Metals) to conduct research at the forefront of aluminum PM science in Canada. Collectively, the team will conduct industrial research in St. Thomas, Ontario with the intent to devise hot forging procedures for a series of emerging aluminum PM alloys recently developed commercially at Ecka Granules or collaboratively at Dalhousie University and GKN. Included are materials designed for exceptionally high strength (Alumix 431D), high strength with enhanced wear resistance (Ecka Alumix 231, Dal/GKN Al-12Si), and sustained strength at elevated temperatures (Dal/GKN Al-15Ni). All are of proven industrial viability from the perspectives of die compaction and sintering and offer mechanical properties in the porous, as-sintered state that surpass those of conventional press-and-sinter aluminum PM blends in current use. Hot forging would enable full densification and significant property improvements, yet retain the key advantage of PM - near-net-shape processing. This innovative knowledge would then be applied in the industrial forging of automotive oil pump gears. Although gears are strategically targeted, a broad scope of applications is ultimately envisioned for this technology. Thus, to enhance the likelihood of widespread adaptation the team will also devise a complete database of mechanical properties and a full assessment of the corrosion behaviour inherent in the forged products. It is hoped that such developments will foster Canadian exploitation of aluminum PM and ultimately position Canada as a legitimate contender in this burgeoning industry.