Subventions et des contributions :

Subvention ou bourse octroyée s'appliquant à plus d'un exercice financier (2017-2018 à 2018-2019).

Nemak Canada is currently introducing a new aluminum engine block into its product line that is based on I6x000D
architecture. This involves development of new casting technology, which shall address exceptionally thin wallx000D
sections, interbore cooling channels, and localized integrated chills. The focus of this research is thex000D
microstructure, mechanical properties and residual stresses in an aluminum alloy engine block that have beenx000D
manufactured with the new technology. Aluminum alloys do not have as high mechanical strength and wearx000D
resistance as compared to, for example, ferrous alloys and are often susceptible to deformation or distortionx000D
during service while under high loads and elevated temperatures, and excessive wear at friction surfaces. Thisx000D
permanent deformation and excessive wear can lead to improper sealing of the combustion chamber, whichx000D
will result in leakage of the air-fuel mixture past the piston rings into the crankcase, known as blow-by. Withx000D
the occurrence of any amount of blow-by, the engine efficiency decreases and fuel consumption and carbon andx000D
NOx emissions rapidly increase. Due to strict environmental laws now commonly enforced in mostx000D
jurisdictions, engines suffering from blow-by would require expensive recalls, resulting in significant financialx000D
losses for the automotive industry. Mechanical properties are highly dependent on alloy composition andx000D
microstructure. To secure the engine block quality is it therefore important to understand how microstructurex000D
and residual stress evolve at each stage of the manufacturing process (casting, heat treatment, and machining).x000D
The first objective of this research is to analyze the microstructure and residual stresses for each stage of thex000D
manufacturing process. This will allow to identify the stage(s) during manufacturing that may lead tox000D
detrimental microstructural changes or high residual stresses that contribute to component premature failurex000D
during service. The second objective is to study how cast-in chills influence the post casting heat treatment.x000D
This will enable optimization of the casting and heat treatment process to enhance alloy mechanical propertiesx000D
and thus provide OEMs a new lighter material for engine blocks that will increase automobile fuel efficiency.