The automotive manufacturing industry is facing an interesting period of trial when a lot of improvement is expected of them in a short period of time to contribute to a cleaner planet by applying technologies that will reduce fossil fuel consumption. Electrification was good, but this must be accompanied by substantial curb weight reduction, which was provided by alloys such as A365, Aural 5 (AlSi8MnMg), Aural 2 (AlSi10MnMg), and Mercalloy 367 (AlSi9MgMnSr) for making structural parts. The use of these Al alloys is accompanied with extensive heat treatment which on its own involves fossil fuel consumption. In this research, test plates were made utilizing high vacuum high pressure die casting (HVHPDC) and a unique Al-Fe based eutectic alloy with Zn and Mg as precipitation strengtheners. Experimental results demonstrated that they age naturally, with their mechanical properties rising to the industry requirement within three days. DSC experiments carried out at various ages gave further experimental evidence to this natural ageing phenomenon. A portion of the samples was then given an experimental "paint bake" treatment at different ages. This is typical on an assembly line where the coated parts are baked at a temperature range of 120 - 200oC for thirty minutes. It was evidently defensible that samples of various ages respond to the treatment in different ways. The mechanical characteristics of the samples decreased after treatment to same value and progressively increased to match the values of the control samples. During the duration of the experiment, some samples rose quickly while others remained "nearly dead" in the state of low mechanical characteristics or climbed sluggishly to catch up with the natural ageing curve. The poorest results were seen in samples handled at the early stage when the initial clusters are forming indicating that it might not be a good idea to interfere with the NA process at those times. / Thesis / Master of Applied Science (MASc) / Fueled by the desire to produce an Al alloy with good mechanical properties arising from natural ageing, high vacuum high pressure die casting (HVHPDC) was used in making castings of this alloy which contains Fe for improvement on its castability and recyclability, contains Zn and Mg which act as the precipitating strengtheners driving the natural ageing phenomenon. Tests and experiments like uniaxial tensile tests, differential scanning calorimetry and electrical conductivity tests were carried out to ascertain its suitability to be used for structural automotive parts without heat treatment. The results showed that the new Nemalloy HE700 met with the minimum industry requirements for mechanical properties of materials for structural automotive applications within 3 days of natural ageing. The alloy was then subjected to experimental paint bake treatment to observe its reaction to paint bake process and the results were able to show when to do paint bake for best outcome.
| Identifer | oai:union.ndltd.org:mcmaster.ca/oai:macsphere.mcmaster.ca:11375/28954 |
| Date | January 2023 |
| Creators | Orji, Chimaobi |
| Contributors | Shankar, Sumanth, Hamed, Mohamed, Mechanical Engineering |
| Source Sets | McMaster University |
| Language | English |
| Detected Language | English |
| Type | Thesis |
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