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Quality control and improvement of the aluminum alloy castings for the next generation of engine block cast components.

机译：用于下一代发动机缸体铸件的铝合金铸件的质量控制和改进。

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摘要

This research focuses on the quality control and improvement of the W319 aluminum alloy engine blocks produced at the NEMAK Windsor Aluminum Plant (WAP). The present WAP Quality Control (QC) system was critically evaluated using the cause and effect diagram and therefore, a novel Plant Wide Quality Control (PWQC) system is proposed. This new QC system presents novel tools for off line as well as on line quality control. The off line tool uses heating curve analysis for the grading of the ingot suppliers. The on line tool utilizes Tukey control charts of the Thermal Analysis (TA) parameters for statistical process control. An Artificial Neural Network (ANN) model has also been developed for the on-line prediction and control of the Silicon Modification Level (SiML).;The student t-statistical analysis has shown that even small scale variations in the Fe and Mn levels significantly affect the shrink porosity level of the 3.0L V6 engine block bulkhead. When the Fe and Mn levels are closer to their upper specification limits (0.4 wt.% and 0.3wt.%, respectively), the probability of low bulkhead shrink porosity is as high as 0.73. Elevated levels of Sn (∼0.04 wt.%) and Pb (∼0.03 wt.%) were found to lower the Brinell Hardness (HB) of the V6 bulkhead after the Thermal Sand Removal (TSR) and Artificial Aging (AA) processes. Therefore, Sn and Pb levels must be kept below 0.0050 wt.% and 0.02 wt.%, respectively, to satisfy the bulkhead HB requirements.;The Cosworth electromagnetic pump reliability studies have indicated that the life of the pump has increased from 19,505 castings to 43,904 castings (225% increase) after the implementation of preventive maintenance. The optimum preventive maintenance period of the pump was calculated to be 43,000 castings.;The solution treatment parameters (temperature and time) of the Novel Solution Treatment during the Solidification (NSTS) Process were optimized using ANN and the Simulated Annealing (SA) algorithm. The optimal NSTS process (516°C and 66 minutes) would significantly reduce the present Thermal Sand Removal (TSR) time (4 hours) and would avoid the problem of incipient melting without sacrificing the mechanical properties.;In order to improve the cast component characteristics and to lower the alloy price, a new alloy, Al 332, (Si=10.5 wt.% & Cu=2 wt.%) was developed by optimizing the Si and Cu levels of 3XX Al alloys as a replacement for the W319 alloy. The predicted as cast characteristics of the new alloy were found to satisfy the requirements of Ford engineering specification WSE-M2A-151-A2/A4.*.;*This dissertation is a compound document (contains both a paper copy and a CD as part of the dissertation).
机译：这项研究的重点是对NEMAK温莎铝厂（WAP）生产的W319铝合金发动机缸体的质量控制和改进。使用因果图对当前的WAP质量控制（QC）系统进行了严格的评估，因此，提出了一种新颖的全厂质量控制（PWQC）系统。这个新的QC系统为离线和在线质量控制提供了新颖的工具。离线工具使用加热曲线分析对铸锭供应商进行评级。在线工具利用热分析（TA）参数的Tukey控制图进行统计过程控制。还开发了一种人工神经网络（ANN）模型来在线预测和控制硅改性水平（SiML）。学生的t统计分析表明，即使铁和锰水平的小范围变化也显着影响3.0升V6发动机机体舱壁的收缩孔隙率水平。当Fe和Mn含量接近其规格上限（分别为0.4 wt。％和0.3 wt。％）时，低舱壁收缩孔隙率的可能性高达0.73。发现在热除砂（TSR）和人工时效（AA）处理之后，升高的Sn（〜0.04 wt。％）和Pb（〜0.03 wt。％）含量会降低V6舱壁的布氏硬度（HB）。因此，为了满足舱壁HB的要求，必须分别将Sn和Pb的含量保持在0.0050 wt。％以下和0.02 wt。％以下。Cosworth电磁泵的可靠性研究表明，泵的使用寿命已从19,505铸件增加到进行预防性维护后，铸件数量达43,904件（增加225％）。计算得出该泵的最佳预防性维护周期为43,000个铸件。;使用ANN和模拟退火（SA）算法优化了凝固（NSTS）过程中新型固溶处理的固溶处理参数（温度和时间）。最佳的NSTS工艺（516°C和66分钟）将显着减少当前的热除砂（TSR）时间（4小时），并避免了初期熔化的问题，而又不影响机械性能。特性并降低合金价格，通过优化3XX铝合金的Si和Cu含量，开发了一种新合金Al 332（Si = 10.5 wt。％和Cu = 2 wt。％），以替代W319合金。发现该新合金的铸造预测特性满足福特工程规范WSE-M2A-151-A2 / A4的要求。*。*本文是复合文件（一部分包含纸质副本和CD）论文）。

著录项

  • 作者

    Francis, Robin.;

  • 作者单位

    University of Windsor (Canada).;

  • 授予单位 University of Windsor (Canada).;
  • 学科 Engineering Industrial.;Engineering Mechanical.;Engineering Automotive.
  • 学位 Ph.D.
  • 年度 2005
  • 页码 228 p.
  • 总页数 228
  • 原文格式 PDF
  • 正文语种 eng
  • 中图分类
  • 关键词

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