EUREKA PROJECT > 4918 ALMAG
UKRAINE
Estimation of applicability of the Ukrainian cast piston alloy based on ternary Al-Me-Si system for automobile industry
In this project the applicability of a new generation of heat resistance eutectic alloy based on the ternary Al-Me-Si system for manufacturing automobile parts will be studied. The properties, resistance to fatigue, corrosion and wear will be performed, including final certification.
Status > ANNOUNCED - 28-Jun-2009 Technological Area Market Area Start Date > 01-Feb-2009 Duration > 48 Months Participating countries > UKRAINE, SPAIN | Main contactACADEMY OF SCIENCES/INST. FOR PROBLEMS OF MATERIALS SCIENCE
Prof. Yuly Milman > TEAM LEADER - Cor. Member, Organisation type > Research Institute |
Project Description
A novel group of cast aluminium alloys was elaborated by Ukrainian scientists on the basis of fundamental works in phase transformation and physics of strength. The approach for this project is based on using ternary phase diagrams which have quasi-binary sections of eutectic type between the solid solution on an aluminium basis and inter-metallic phases. Due to purposeful alloying, the different mechanisms of strengthening (the composition-, solid solution-, and dispersion-involved ones) are realised. These alloys possess high melting temperatures which are greater than those of other cast alloys. This provides a substantial increase of operational characteristics of cast eutectic aluminium based alloys especially at elevated temperatures. The ideology allows for purposefully changing the properties of cast eutectic aluminium based alloys. It was shown that new aluminium cast alloys on the basis of the Al-Me-Si system offer some preferences over silumins: - Higher heat resistance which is necessary under conditions of piston work for both the bottom and grooves; - Good casting characteristics; - High wear-resistance which is important while working in the zone of piston grooves, gudgeon pin boss, and piston skirt; - Lessening of piston weight due to high magnesium content which is very essential for modern engines. International collaboration is based on using the scientific, technical and financial resources of UKRAINE and SPAIN as well as financing due to participation in European programmes. Ukrainian party: The Frantsevich Institute for Problems of Materials Science, NATIONAL ACADEMY OF SCIENCE OF UKRAINE * Optimises the composition of the content of an eutectic alloy on the basis of an Al-Me-Si ternary system on the main and alloying components in accordance with given demands and determines the level of mechanical tensile properties (tensile strength, yield strength, elongation at room and elevated temperatures) and wear of laboratory ingots. * Establishes the optimal temperature-time relationships of smelting of ingot up to 20 kg, made up of the master alloys from SPAIN. * Delivers ingots with general weight of 300 kg to TARABUSI. Spanish party: TARABUSI (CIE Automotive Group), with subcontracting from TEKNIKER * Develops the requirements specification of the test materials. * Provides requested master alloys. * Manufactures samples from the ingots. * Tests corrosion properties. * Tests friction and wear properties. * Tests mechanical properties (tension tests and fatigue tests at high temperatures). * Tests residual stresses. * Manufactures pistons. * Carries out tribological simulations of piston components. * Carries out engine testing. Project implementation presupposes joint patenting of a new cast alloy and its usage.
Technological Development Envisaged
INTRODUCTION AND OVERVIEW The fundamental authors’ works in the field of phase transformations and physics of strength [1-3] are the physical base for creation of the new class of cast aluminium alloys, some of which are protected by our own patents [4,5]. To design the modern cast alloys for the piston group, the ternary Al-Me-Si system was selected as the base system. The wide region of existence of uni-variant eutectic transformation in such systems allows us to change a proportion of components of alloys within wide limits without changing its phase composition. The alloys, the compositions of which are situated on the quasi binary sections of the phase diagrams, are the most suitable for such requirements. These alloys have a high eutectic temperature, with a high volume part of the reinforcing phase in eutectic and with phase composition, which is stable under alloying. Optimisation of the alloying system was carried out taking into account the concentration-temperature parameters of eutectic transformation, thermal stability and phase composition. Due to purposeful alloying, the different systems of particles, which should not interact with eutectic colonies and which are stable in certain temperature intervals, are created in the matrix of eutectic alloys. This approach promises the premeditated level of physical and mechanical properties [2]. According to this, the two potentiality groups of alloys were developed: for high-temperature application and for operating up to 150 degrees Celsius. The project includes the following parts: * Establishment of the connection between the microstructure of eutectic alloys based on the ternary Al-Me-Si system after their thermal treatment and the mechanical and tribo-technical properties; * Selection of the variants of a piston alloy (optimisation of the basic and alloying components) by the results of laboratory tests; * Casting of a pilot batch of pistons, and implementation of technological (the estimation of workability) and bench tests on engines. REFERENCES: 1. Milman Yu.V. High-strength aluminum alloys. Metallic Materials with High Structural Efficiency. Eds.: O.Senkov, D.Miracle and S.Firstov. Kluwer Academic Publishers, 2004, p.139. 2. Barabash O.M., Milman Yu.V., Korzhova N.P., Legkaya T.N., Podrezov Yu.N. Design of new cast aluminium materials using properties of monovariant eutectic transformation L -Al + Mg2Si. Materials Science Forum, 2002, 396-402, p.729. 3. Barabash O.M., Sulzhenko O.V., Legkaya T.N., Korzhova N.P. Experimental Analysis and Thermodynamic Calculation of the Structural Regularities in the Fusion Diagram of the System of Alloys Al-Mg-Si. Journal of Phase Equilibria, 2001, Vol.22, No.1, p.5. 4. Pat. 2224811 RU, С22 С 21/06, Cast aluminium alloy. Bull. 6, 2004. 5. Pat. 72560 UA, C22C21/08, 21/06 21/00. Cast aluminium alloy. Bull. 3, 2005
Main contactAcademy of Sciences / Institute for Metal Physics Dr. Legka > Senior Scientist Organisation type > Research Institute |
Contribution to project
The contribution from IMP to the project is the following: - Selection of base compositions and choice of alloying system for realisation of the mechanisms of dispersion and solid solution strengthening of piston alloy; - Optimisation of alloying system taking into account the concentration-temperature parameters of eutectic transformation, thermal stability and phase composition of the multi-component eutectic alloy; - Determination of the parameters of smelting and pouring laboratory ingots of the proposed eutectic alloy. Structure, thermal characteristics, and mechanical and tribological properties will be investigated on the following facilities: light microscope NEOPHOT-32 with digital camera; equipment for thermal analysis TA-1.
Expertise
IMP scientists have excellent experience in the field of phase transformations and physics of composition materials, particularly in the theory and practice of physics of eutectic alloy crystallisation. In their scientific activity, a complex approach to this problem takes place: from thermodynamic calculations of the phase equilibriums in multi-component systems to experimental investigations of regularities of structure formation in eutectic alloys. In their works, the modern approach to creation of a new generation of high-strength cast aluminium alloys and high-modulus alloys on the base of aluminium inter-metallics is developed, in which the fundamental investigations and applied creations combine well.
Main contactTARABUSI S.A. Eng. INAKI ILLARRAMENDI > PRODUCT MANAGER Organisation type > Large company |
Contribution to project
The contribution from TARABUSI in the project is the following: - Definition of the specifications of the ternary alloys. - Supply of the Al Master alloys. - Definition of the tests to be carried out (testing conditions). - Fatigue tests. TARABUSI will subcontract the activity from TEKNIKER. The following activities will be carried out by TEKNIKER: - SEM analysis; - Residual stress analysis; - Mechanisation of specimens; - Tribological properties under engine working conditions; - Analysis of the wear of engine components; - Evaluation of the corrosion resistance.
Expertise
The company TARABUSI has participated in several EU projects and also projects with industrial companies: - NANOMAG "Development of magnesium pistons"; - SEPMAC "Mechanisation of magnesium pistons"; - Nano-HVOF "Development of piston ring coatings with nano-HVOF"; - EREBIO "Development of materials and lubricants to improve the engines". TARABUSI is the owner of several patents. TARABUSI and TEKNIKER have participated in the COST 532 Action. In the frame of this action, they knew Prof. Milman, and collaboration started. The Tribology Unit from TEKNIKER is participating in this project, represented by Dr. Amaya Igartua. TEKNIKER will participate in the Spanish project as subcontractor of TARABUSI.
Main contactACADEMY OF SCIENCES/INST. FOR PROBLEMS OF MATERIALS SCIENCE
Prof. Yuly Milman > TEAM LEADER - Cor. Member, Organisation type > Research Institute |
Contribution to project
Estimation of opportunities of melting ingots with the set properties from industrial standard master alloys. Ingots up to 20 kg and up to 160 mm in diameter are going to be smelted in an induction melting furnace with a graphite crucible from master alloys. Then the melt will be poured into a special water-cooled chill mould. Structure, thermal characteristics, mechanical and tribological properties will be investigated using the following facilities: light microscope NEOPHOT-32 with digital camera; equipment for differential thermal analysis VDTA-8; machine for mechanical testing at elevated temperatures 1253-U-2-2 and computer-assistant tribology complex CATC.
Expertise
The activity of the Ukrainian scientists is devoted to physics of strength and fracture of a wide class of materials: aluminium alloys, refractory metals, diamond, covalent crystals and ceramics on their base, amorphous metallic alloys and quasi-crystalline materials. Ukrainian scientists have excellent experience in the field of developing both the composition and the procedure of novel materials, their testing and patenting. The Ukrainian contribution comprises the development of essentially new high-strength cast aluminium alloy for diesel engines. Participation in this project will allow for deepening theoretical and applied representations of materials science, and also promoting the integration of scientific experience of the Ukrainian scientists and scientists from other countries and establishing new creative contacts.