Grant: Alliance Grants

The goal of this partnership is to generate new knowledge on the processing, microstructure and properties of a bi-metal casting and metal-metal matrix composite (MMC) castings. The stress field experienced by a 3D component processed for Castings and Additive Manufacturing (AM) of lattice structures will be evaluated using Finite Element Modelling (FEM). Manufacturing of the castings with 3D lattice structures provides freedom of design and manufacture of complex parts. The research will be carried out in three phases. Phase 1 (years 1 and 2) will be the processing of laboratory samples of cylinders composed of a bi-metallic part, and a metallic part joined to an MMC. The mechanical properties of both systems will be evaluated. In Phase 2 (years 1 to 4), different lattice structural architectures will be evaluated using FEM. The most promising structure from FEM results will be compared with built lattices in Phase 3. Phase 3 (years 2 to 4) will address the filling of the candidate lattice and alloy with varying compositions: Cr-white iron and carbon steel, and NiBSi with WC composite and carbon steel. Subsequent evaluation of fill density, microstructure, and wear will be carried out. A foundry (TBD) will be used to make test components and samples. This will be followed by microstructural characterization of the component and field testing by the Partner. For HQP, two graduate students will be recruited for the project and partial time of two Research Associates will contribute. The graduate studetns will be recruited from a wide pool of potential applicants in order to ensure inclusivity and diversity of the recruited population.