Planned 2010 Project Presentations
 

 

Planned 2010
Project Presenter(s)

Morning 8:00-12:00P
 

8:00-8:15
 

Introductions

8:15-8:30

AMD 309 – Aluminum Automotive Closures Panel Corrosion Test Program

This project has been completed and the final report has been submitted to USAMP.  This presentation will summarize the results of the final testing of the modified ASTM G85-A2 test and the conclusions of the final report.  In addition, recommendations to standardize the modified test method will be shared. 

Janice Tardiff (Ford)

8:30-9:00

AMD 603 - Mg Front End Design and Development (MFEDD) Phase I. Design and Feasibility Study

This presentation summarizes the final design and cost analysis results of magnesium front end structures for two body architectures (a rear-wheel-drive unibody and a body-on-frame). The magnesium designs offer up to 45% mass saving compared to baseline steel structure.

Alan Luo (GM)

9:00-9:30

AMD 604 - Mg Front End Research and Development (MFERD) Phase I. Enabling Technology Development

This presentation summarizes the recently completed US-Canada-China collaborative project in the following task areas: Crashworthiness; Noise, vibration and harshness; Fatigue and durability; Corrosion and coatings; Extrusion & forming; Sheet & forming; High-integrity body casting development, with an update on Welding and joining. The results are generally applicable to all magnesium applications especially in body structures.

Alan Luo (GM)

9:30-10:00

AMD 702 and 703 - Integrated Computational Materials Engineering (ICME) for Mg International Pilot Project

The goal of this project is to develop an ICME infrastructure for advanced lightweight magnesium processes and alloys for body applications.  Quantitative processing-microstructure-property relationships are being developed and captured in databases and models to enable alloy and manufacturing process optimization for high-integrity magnesium castings, extrusions and sheet product.  The program is being conducted as research collaboration between researchers and organizations in Canada, China and the United States.

Mei Li (Ford)

10:00-
10:15

BREAK

 

10:15-10:45

AMD 704 - Development of Steel Fastener Nano-Ceramic Coatings for Corrosion Protection of Magnesium Parts

The AMD-704 project is investigating the potential of applying nano-ceramic coatings to steel fasteners to eliminate galvanic corrosion between magnesium components and steel fasteners.  Ceramic nano-layer coatings (thin films) have demonstrated uncharacteristic properties with improved strength and ductility versus traditional bulk ceramic materials.   These properties coupled with improved interfacial adhesion to steel substrates suggest the potential to create true barrier coatings that can limit galvanic current and, consequently, corrosion between dissimilar metal joints like steel fasteners and magnesium components.  This presentation will discuss the results from Phase 1 of the project and the remaining work in Phase 2.

Dick Osborne (GM)

10:45-11:15

AMD 904 - Magnesium Front End Research and Development (MFERD) Phase 2 Technology Development and Demonstration

This presentation provides an introduction  and status update for the follow-on Phase II US-Canada-China collaborative project, which will focus on producing magnesium-intensive surrogate structural assemblies for validation and testing of manufacturing methods, materials performance, and durability, using technologies advanced in Phase I.

Alan Luo (GM)

11:15-11:45

LUNCH

11:45-12:15

AMD 905 - Optimization of High-Volume Warm Forming for Lightweight Sheet Alloys

Successful completion of two projects on warm forming (AMD307 and AMD602) has shown that this technology can be used as a cost-effective method of manufacturing complex 3-dimensional panels from both aluminum and magnesium sheet alloys. The new AMD905 project is focused on further optimization of the warm forming process that will bring the technology to a implementation ready status and develop a supply base for warm forming.  Specific objectives include development of a non-isothermal warm forming process that both enhances formability and allows for the use of lower-cost heating methods, demonstration of the enhanced process on a complex panel and finally partner with a supplier to implement the production process.

Ravi Verma (GM) / Peter Friedman (Ford)

12:15-12:45

AMD 1001 - Corrosion Inhibiting Electrocoat Systems

The project is to develop corrosion inhibiting coatings systems for body-in-white (BIW) assemblies. The goals are a robust paint-line compatible pretreatment process for magnesium intensive vehicles and incorporation of corrosion inhibiting compounds into electrocoat formulations. Assessment of new pretreatment processes for magnesium alloy parts has been initiated and preliminary results indicate that a rare-earth based coating can be deposited onto Mg, Al, and Mg-Al couples. Electrochemical characterization and salt spray testing have demonstrated that passivation and protection of the substrate materials occurs using the proper processing conditions.  This presentation will highlight the project plans and preliminary findings of this new project.

Yar-Ming Wang (GM)

12:45-1:15

AMD 1003 - Global Vehicle Assessment

This project proposes to improve the breadth of benchmarking data to USAMP OEM's with a goal to enable and lead directly to timely implementation of high impact light-weighting technologies in the North American vehicle fleet. This effort will implement a shared full vehicle teardown and assessment process that seeks to find and  present ideas for new light-weighting technologies not previously under consideration for development and proposes to identify more cost effective methods to improve light-weighting of vehicle structures. This presentation will discuss the approach, tasks, analysis procedures and deliverables to achieve the objectives of this recently launched project.

Shawn Morgans (Ford)

1:15-1:30

BREAK

Afternoon Session 1:30-3:30

1:30-1:45

AMD 304 - Magnesium Powertrain Cast Components

The Magnesium Powertrain Cast Components Project demonstrated the technical and economic feasibility of creating a magnesium-intensive engine and in doing so, reduced the mass of the cast components of engine by nearly 30% relative to the original aluminum components. The project team encountered and overcame several significant challenges to achieve these goals. The presentation identifies and describes the lessons learned during this project.

Bob Powell (GM)

1:45-2:00

AMD 410 - Powder Metal Performance Modeling of Automotive Components 

The objective of this program is to develop and experimentally validate math-based models for powder metallurgy production processes and performance prediction.  The multi-state porosity-microstructure-property model is applied to low-strain rate, high strain rate and fatigue environments to evaluate and optimize an automotive component design (main bearing cap) as affected by the materials and manufacturing processes.

Shekhar Wakade (GM)

Paulo Rosa (Chrysler)

2:00-2:15

AMD 405 - Improved Automotive Suspension Components Cast with B206 Alloy

The B206 aluminum alloy is a lower cost alternative to aluminum forgings and provides a lightweight alternative to ferrous materials for suspension applications.  This project cast B206 aluminum control arms, modeled after an OEM forged 6082-T6 control arm, using semi-permanent mold and ablation casting processes.  The control arms exhibited mechanical properties superior to that of the forged aluminum control arm.  This presentation will summarize the findings of the completed program, which includes discussions on chemistry optimization, stress corrosion cracking susceptibility testing, cost modeling and casting trials.

Dick Osborne (GM)/ Eric McCarty

2:15-2:45

AMD 601 - High Integrity Magnesium Automotive Castings (HI-MAC)

The High Integrity Magnesium Automotive Component project (HIMAC) objectives were to: develop and validate existing aluminum casting process technologies needed to manufacture Squeeze and Low-Pressure Permanent Mold (LPPM) cast magnesium automotive suspension components; evaluate the potential of emerging castings technologies, specifically the Ablation; T-Mag and molten-metal transfer/filling using an electromagnetic pump.  These processes for the casting of magnesium components; address critical technology barriers inhibiting automotive industries use of magnesium applications.  Identical magnesium control arms were produced from all of the above processes and evaluated for; x-ray internal cast integrity, static and cyclic material properties.

Dick Osborne (GM)/ Don Penrod

2:45-3:00

NDE 901 - Reliability Tools for Resonance Inspection of Light Metal Castings

Resonance inspection uses shifts in the “natural” vibrational frequencies of a component to rapidly and efficiently detect discrepant conditions such as cracks, voids, inclusions, and poor heat treatment.  We will review progress on quantifying and simulating the shifts in three aluminum castings due to discrepancies as well as due to normal dimensional and material variations.

Martin Jones (Ford)

3:00-3:15

NDE 1002 -Shearographic Nondestructive Evaluation (NDE) of Spot Welds for Lightweighting of the Vehicle

Shearography measures surface strain on slightly perturbed components.  Information about spot weld nuggets will be extracted from finite element analysis using this 2D strain field as input.  We will review project objectives, timing and goals.

Martin Jones (Ford)

3:15-3:30

Closing Remarks