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Given the increasing demand for resource-efficient, high-strength and lightweight structures and the associated challenges in processing such materials, the development and research of new innovative materials with superior properties is essential.
Steel is known for its high strength and toughness and is the most widely used metal in the world, particularly in the construction and transportation industries. Aluminum, on the other hand, is the most abundant metallic element in the earth's crust and has special properties such as low weight (about three times lighter than steel, but higher strength-to-weight ratio), excellent corrosion resistance, high thermal conductivity, etc. By combining aluminum and steel, the special properties of the individual components can be used to create a single component with high strength, low weight and good corrosion resistance. This leads to resource-efficient, sustainable and improved fuel economy.
In this project, we pursue a combined approach to materials research, which includes experiments, advanced material characterization and modelling. The aim is to holistically investigate and characterize intermetallic layers that form during the composite casting of different materials (aluminum and steel) and to determine optimal parameters to achieve maximum bonding and best mechanical properties with the shortest possible holding time during composite casting. In addition, we develop and validate models to predict the growth kinetics of these layers, which can then be generalized and used for other component systems. Furthermore, thermodynamic calculations using CALPHAD will be performed to corroborate the experimental results and investigate the stability of the phase(s) that form in the junction zone at different temperatures and compositions. Finally, the prediction and modeling of the growth kinetics of intermetallic layers during composite casting will be implemented in OpenFoam.
Funding: DFG
Project partner: Chair of Forming Technology and Foundry Engineering, Technical University of Munich
Duration: January 15, 2024 - January 14, 2026
Responsible:Chukwuemeka Lucky Ihemaguba