Metal Casting Expertise at the Industrial Materials Institute (IMI)

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Research activities in metal casting at IMI are designed to provide industry with the leading edge manufacturing technologies needed to compete in a global economy. The work is focused on developing a thorough understanding of the processes which allow us to offer to companies the support for processes/products development, optimization and control.

Metal Casting Technologies

Die Casting of Aluminum and Magnesium Alloys and their Composites

IMI is conducting research programs in die-casting and gravity casting of aluminum and magnesium alloys and their composites. It is equipped with an industrial scale semi-solid die-casting machine and simulation facilities to undertake studies such as :

• The validation of flow and solidification predictions from numerical analyses
• The evaluation of new alloys and lubricants for die-casting
• The influence of casting parameters on mechanical properties and residual stresses
• The flow and solidification behaviour of semi-solid die-casting alloys

Experimental Investigation of Solidification in Casting Processes

• Study of prevailing solidification conditions at mould-liquid interface (nucleation and heat transfer)
• Improvement of as-cast surfaces and control of heat flux at the interface between the mould and the casting
• Evaluation of the influence of various parameters such as mould material, surface conditions (texture and coatings) on surface quality and internal microstructure
• Evaluation of the influence of factors like the atmosphere and the application of sonic vibrations during solidification

Development of Strip Casting of Steel, Copper and Aluminum Alloys and MMC's

IMI has acquired a considerable expertise in the field of twin-roll strip casting of various alloys. This casting process consists in the production of thin strip directly from the molten metal without hot rolling. Work was carried out in collaboration with a consortium of six major Canadian steel producers to develop the twin-roll casting process for carbon steel. Further work was carried out for the development of the twin-roll casting process for aluminum and copper alloys and non metallic materials.

Surface Technologies for Mold Coating

IMI has an internationally recognized expertise in the development of technologies such as thermal spraying (plasma, high velocity oxy-fuel, flame and arc spraying). Various metallic and cermet coatings have been developed to improve the resistance of parts in severe environments such as high temperature, corrosive media and abrasive wear. Potential benefits in casting processes are longer mould and die life, prevention of bonding, wear resistance and selective control of heat transfer at the mould-part interface.

Simulation and Instrumentation for Casting Processes

Computer Modelling and Casting Simulation Technologies

IMI has developed parallel finite element software technology capable of modelling mould filling, solidification and residual stresses for pressure die casting, permanent casting, semi-solid casting and sand casting. Using this parallel simulation tool, numerous projects were conducted with industrial partners on process and design optimization with benefits such as reductions in process development times, troubleshooting casting problems and improved casting quality.

Projects were conducted on a wide variety of products such as piston head, valve cover, axle tube, engine front cover, car wheel, transfer case, bracket, seat frame, alternator housing, lawnmower deck, high-voltage line tensionner and other electro-mechanical components.

Ultrasonic and Optical Sensing Technologies for Process and Quality Control

The ultrasonic sensors use specially developed buffer rods for reliable continuous coupling to hot moulds. Sensors which can be deposited on a mould surface using an innovative sol-gel process and can operate as well at elevated temperature are also in development. These ultrasonic sensors :

• allow to monitor the flow front and the end of filling
• allow to follow cooling and solidification
• indicate part detachment
• can measure liquid temperature
• can provide information on the part microstructure

These sensors have been used for monitoring high-pressure die casting and are applicable to semi-solid die casting and thixomolding. Thermographic inspection has also been used to measure mould and part temperature after moulding. This information has been used to optimize cooling channels resulting in high quality parts with reduced numbers of defects.

Equipments Available

Equipment for Metals Casting

A 600T capacity Buhler SC N/53 die casting system with real-time control, together with a set of fully instrumented dies. The machine is used for semi-solid casting with two different induction heating systems for rheocast billets.

Equipment for Solidification and Casting Studies

• Dip test apparatus to investigate the influence of substrate texture and coatings during solidification
• Electrostatic powder spraying equipment
• Full size water model of the twin-roll strip casting machine

Laboratory Equipment and Computational Capabilities

• Scanning electron microscopes
• Thermal spraying and coating systems (plasma, HVOF, arc and flame)
• DSC and DTA systems
• Apparatus for thermal expansion and thermal conductivity measurements
• Mechanical test equipment (tensile, fatigue and impact)
• 3D laser scanner, ultrasonic and infrared systems
• IBM and SGI computers (some with multiple processors)

For more information and to give your company a technological advantage, we encourage you to contact IMI representatives.

François Hamel, Group Leader Multi-Materials Applications Tel. : (450) 641-5234 Fax : (450) 641-5105 E-mail: Francois.Hamel@cnrc-nrc.gc.ca
Nafez Melhem, Eng. Liaison Officer Tel.: (450) 641-5291 Fax: (450) 641-5101 E-mail : Nafez.Melhem@cnrc-nrc.gc.ca
Alain Simard, Eng., M.Sc. Business Development and Communication Officer Tel.: (418) 545-5099 Fax: (418) 545-5543 E-mail: Alain.Simard@cnrc-nrc.gc.ca

Related Information

Institutes:

• NRC Industrial Materials Institute