Grant: Discovery Grants Program - Individual

Over the past 15 years, magnesium (Mg) usage in automobiles has significantly increased by about 15% annually. The average Mg content in the 2007 model cars was about 6 kg, and is expected to increase to 160 kg by 2020. Currently, Mg automotive applications are produced by conventional high pressure die casting (HPDC) processes, which result in materials with high porosity content and low strengths. Recent studies have demonstrated that the squeeze casting process is able to significantly eliminate porosity and other casting defects in magnesium alloys. However, squeeze casting is relatively costly compared with conventional HPDC due to higher process operation and tooling costs. To maximize the engineering performance and quality of Mg squeeze castings at a competitive cost, the squeeze casting process needs to be optimized. The proposed project intends to develop an optimal technology for manufacturing integrity cast Mg automotive components such as control arms and knuckles, which are thick-wall castings with various cross section thicknesses. The work will include development and fabrication of an integrated step-die incorporating advanced transducers and sensors for pressure and temperature measurements, design detailed experimental matrices by taking into consideration essential process parameters, analyses of microstructure, mechanical and corrosion behaviours of squeeze cast conventional (Mg-Al) and high temperature Ca and/or Sr-containing Mg alloys, and optimization of the process by employing an appropriate optimization methodology with comprehensive assessment of the properties of various alloys. The outcome of the project will help maintain Canada's leadership in the world in producing light weight Mg automotive components since Canada is presently hosting the largest die casting producers of Mg in the world with the presence of Meridian Lightweight Technologies in Ontario and TriMag in Quebec. The success in the development of new processes for potential advanced components will lead to an increase in Mg casting shipment in Canada as well as an expansion of world-wide use of Canadian value-added Mg products.