No Light-Weight

In their investigations, the Industrial Research Chair team is developing models of the friction process and new tribological design methods, as well as experimenting with wear-resistant engineered surfaces for industrial applications and final parts. They are also examining the development of ultra-hard surfaces through methods such as the application of nano-crystalline coatings.

He and his team are therefore unravelling the mystery of how the microstructure of these new alloys can be hardened – through heat treatment for example – so that the friction they offer during engine operation is acceptable.

But before these parts can be placed in an engine on an assembly line, they also must be able to withstand the rigors of manufacturing.

“Right now, removing the bits of aluminum that are shaved off during machining requires relatively large amounts of cutting fluids, and these substances present both health and cost issues,” notes Alpas. “We’re moving towards a point where because of their chemical properties, they will be legislated out of use.” To be able to use near-dry machining on aluminum alloys without sticking issues, Alpas’ team is investigating carbon-based diamond-like coatings.

New coatings and surface technologies are also needed when aluminum alloys are used to form auto parts such as body panels. “During high-temperature (superplastic) forming, the alloys become very stretchy, almost like a viscous fluid,” says Alpas. “This creates an excellent way of forming light weight metal sheets but, once stretched, they stick to the dye, so we are looking at novel surface solutions, using new high temperature coatings and lubricants there as well.”

Obviously, Alpas and others in his field would like to see lighter weight materials widely used in moving vehicle parts as soon as possible, but solving the problems will require a good deal of time.

“The surface tribological issues in automotive materials are so extensive that we’ve just started to scratching the surface,” he says.DE
www.uwindsor.ca/tribology
www.auto21.ca

Treena Hein is an Ottawa-based freelance writer.