Prof. Diran Apelian

Alcoa-Howmet Professor, Funding Director of

Metal Processing Institute

Worcester Polytechnic Institute (WPI)

Metal casting in the 21st Century – Emerging Trends and Challenges

二十一世纪的金属铸造业 —— 新兴趋势与挑战

METAL CASTING IN THE 21st CENTURY –EMERGING TRENDS AND CHALLENGES

21世纪的金属铸造－发展趋势与挑战

2

Diran ApelianWPI, Worcester, MA 01609 USA

Distinguished Visiting Professor

University of California, Irvine, CA 92697 USA

1984 1991 2010

2018

www.wpi.edu/+mpi

3

铸造研究中心 热处理研究中心 回收利用研究中心

材料生产数据研究中心

这些项目按资金来源分为三类：1）由多位MPI会员共同支持的项目、2）由国家机构支持的项目、以及3）由公司一对一投资的项目。

今天会着重介绍先进铸造研究中心正在进行和已完成的研究项目。

STORYLINE 叙事线

▪ALLOY DESIGN 合金设计

▪RECYCLED METAL – SECONDARY AL 金属回收－二次铝合金

▪MEASURES AND CONTROLS - Molten Metal 熔融金属的成分测量和质量控制

▪MEASURES AND CONTROLS - - Cast Product 铸造产品的成分测量和质量控制

▪PROCESS COGNITION 生产过程交互识别

5

DESIGNERS HAVE

CHOICES

6

产品设计者拥有选择权力

CLASSES OF MATERIALS材料的分类

金属和合金材料

高分子材料

陶瓷和玻璃材料

复合材料

材料特征的分类

经济类特征

宏观机械性能特征

宏观非机械性能特征

表面特征

生产特征

质地特征

YOUNG’S MODULUS

杨氏模量

陶瓷 金属 高分子 复合材料

DENSITY

密度

陶瓷 金属 高分子 复合材料

A Retrospective view铝合金发展回顾

11

“Employ another metal instead of iron”

“Copper?” said Morgan

“No! That would be too heavy. I have better than that to offer.”

“What then?” asked the major.

“Aluminium!” replied Barbicane.

“Aluminium?” cried his three colleagues in chorus.

Jules Verne: “From the Earth to the Moon” – 1865

儒勒凡尔纳：“月球旅行记”－1865

The Aluminium Capsule is Being Shot into Space (Chapter 7)

铝制胶囊被投送到太空（第7章）

“Unquestionably, my friends. This valuable metal possesses the whiteness of silver, the indestructibility of gold, the tenacity of iron, the fusibility of copper, the lightness of glass. It is easily wrought, is very widely distributed, forming the base of most of the rocks, is three times

lighter than iron, and seems to have been created for the express purpose of furnishing us with the

material for our projectile.” （…铝合金具备银的白洁，金的延展性，铁的坚韧，铜的流动，轻如玻璃。它可以形变，而且矿石广泛分布，密度仅有铁的1/3…)

▪ Discovered by accident in 1906 by WilmIn the course of a study to replace the heavy brass alloy that was used to make the jacket material for cartridges with an aluminum alloy for weight savings. He was working with an Al-Cu-Mn alloy. Wilm在一次研究利用铝替代黄铜做的弹壳

的研究中，他偶然发现了Al-Cu-Mg合金。

▪ His initial results were published in 1911 在1911年第一次发表研究结果。

▪ He could not observe the microstructural changes and the source

of the increased hardness remained a mystery 但是当时由于不能观测

到显微组织结构，因此该合金的高强度成为谜一般的存在。

Strengthening with Second Phases第二相强化机理

– precipitation hardening 析出强化 –

▪ Wilm produced the first commercial alloy in 1909. It had the trade name Duralumin Wilm在1909年制作了第一批商用合金，并赋予其商业交易名称Duralumin。

▪ Composition 成分:

Al–(3-4.5) Cu– 0.4-1) Mg–(0-0.7) Mn

▪ Mirca in 1920 correctly deduced the source of strengthening: results from ‘sub-microscopic’ precipitates produced at temperatures below the solvus Mirca在1920年正确推测强度的提高是由于在固溶线温度以下产生的“光学显微镜所无法看到”的析出物

It was not until the development of the electron microscope in the 1950’s that the nature of the precipitates became physically clear.

直到1950年代随着电子透镜的技术提高才得以揭示析出物的本质

A Pillar Inner

Shock Tower

front & rear

Steering

Column

A Pillar

Outer

Door Structure

B Pillar Top

B Pillar

Bracket

Crossmember / Engine

CradleRear SF node / longitudinal member

C Pillar

High voltage housing

Inner back hatch

reinforcement

Steering

Panel

15

Cast Al Alloys –Basics铸造是铝合金基础

Number Series 编号 Alloy Type 合金类别

1XX.X 99.0% min aluminum content

2XX.X Al + Cu

3XX.X Al + Si & Mg, Al + Si & Cu, or

Al + Si & Mg & Cu

4XX.X Al + Si

5XX.X Al + Mg

7XX.X Al + Zn

8XX.X Al + Sn

6XX.X and 9XX.X reserved for future use

Digit after decimal 小数点后一位: i.e. xxx,X: 0 - cast products 铸件; 1&2 – ingots 铸块

used for xxx, 0 products but with tighter chemistry limits 更严格的化学成分, 2 also tighter than 1

Letter before numbers 数字前的字母: i.e. Axxx.x, Bxxx.x, denote variation on original

designated alloy字母前标表示合金的变种

A Prospective view发展前景

17

Drivers 需求方向

▪HIGH TEMPERATURE (above 250C )耐高温

Al-Si-Ni-TM (TM = Zr, Mn, etc.)

▪HIGH STIFFNESS高模量

HEA▪HIGH ELECTRICAL CONDUCTIVITY高导电性

Al-Zr-Y

18

All Al Alloys (Wrought and Cast)

19

延展率

屈服强度

T. Din and J Campbell: Mater. Sci. Technol., 1996, vol. 12, pp. 644–50.

20

屈服强度

拉伸率

Background

0

50

100

150

200

250

0 50 100 150 200 250 300 350 400

A390(17Si4.5Cu0.6Mg) Die casting T-5

A390(17Si4.5Cu0.6Mg) Die casting-F

336(12Si2.5Ni1Mg1Cu)-T65

Temperature℃

0.2

% Y

ield

Stre

ngth

(MP

a)

Davis, J. R. (Ed.). (1990). Properties and selection: nonferrous alloys and special-purpose materials (Vol. 2) ASM

21

0.2

%屈服强度

温度

Strengthening in Al-Ni-Mn-W-Zr-V Alloys

Al-Ni-Mn-W-Zr-V合金的强化机理

Al3Ni fibers

Al matrix

Grain boundary

L12-Al3(Zr,V)

Al12(Mn,W)

Al3Ni: several 𝜇𝑚 * 100nm rod100纳米直径微米长度针状析出物

Al12(Mn,W):20 nm thick * 250 nm diameter plate20纳米厚度 250纳米直径圆盘析出物

L12-Al3(Zr,V):4~6 nm in radius sphere4~6纳米直径球状析出物

22

Strength of Al-TM alloysAl-TM合金的强化曲线

0

50

100

150

200

250

300

0 50 100 150 200 250 300 350 400

Yiel

d S

tren

gth

e(M

pa)

Temperature ⁰C

A390 Die casting-F

Al-6Ni-2.5Mn-0.8W-0.4Zr-0.4V T6heat treatedAl-6Ni-0.4Zr-0.4V T6 heat treated

Al-6Ni

L12-Al3(Zr,V)

Al3Ni

Al12(Mn,W)

23

屈服强度

温度

THERMODUR 25 PLUS

Commercially Produced by

24

研究所专利成果

授权德国Rheinfelden公司生产

Aluminum Containing “High-Entropy” Alloy (HEA-Al)

铝合金体系的高熵合金

High Entropy Alloys (HEAs)Resembles common crystalline structures where each constituent

randomly populates lattice sites (BCC, FCC, or HCP)

每个组分随机地占据晶格位置,组成通常的晶体结构

BCC (five principal elements) FCC (five principal elements)Schematic illustration of MoTaWNb HEA with

single BCC structure

Lattice Distortion

晶格畸变

Y. Zou, Nature Communications, 2015J.W. Yeh, et al. Metall Trans A, 200426

Entropy-based requirement 基于熵的准则

The term high entropy refers to the magnitude of a mixing entropy in an alloy system 熵指的是合金混融

的程度

Generally △Smix ≥ 1.5R is considered high entropy熵值高于1.5R被认为是高熵值

=

−=n

i

iimix ccRS1

)ln(

ci: the atomic percentage of the ith component elementR: the gas constant, 8.314 JK-1mol-1

△Smix ≤ R

1R ≤ △Smix ≤1.5R

Low entropy alloys(traditional)

Medium entropy alloys

HEAs

△Smix ≥ 1.5 R

High Entropy Alloys (HEAs)

27

Why HEA?

为什么高熵合金有意思？➢ High toughness 高韧性

➢ High temperature softening

resistance抗高温软化

➢ High hardness高硬度

➢ High Oxidation resistance

高抗氧化性能

➢ etc. 等等

Why aluminum?为何选用铝为基体？▪ Aluminum alloys are widely applied in various industries 铝合金应用广泛▪ Taking advantage of Al properties by choosing the matrix to be aluminum (Al＞70%) 发挥铝合金的性能优势把基体选择为铝▪“Reliable” database for aluminum based alloys 可靠的铝合金数据库▪ Fertile terrain – vast opportunity 未被开发的领域－巨大的潜力

Challenges挑战

28

INTEGRATED COMPUTATIONAL MATERIALS ENGINEERING

综合计算材料工程

ICME29

ExperimentsIterationsCALPHAD Approach

Elements of the alloy

Composition of the alloy

Heat treatment

Phase stability regions at different

temperatures

ICME-Alloy Design计算和实验结合的合金设计理念

30

Design Strategies 设计思路

FCC

Str

uct

ure • Al-rich alloy 富铝合

金

• Minimize the secondary phases in the FCC matrix减少在基体中的析出物

• Consider coherent secondary phases考虑共格析出物

Eute

ctic

Str

uct

ure

• Al-rich alloy 富铝合金

• Consider the eutectic compositio共晶成分

• Consider the precipitation hardeners and stabilizers考虑析出强化

BC

C S

tru

ctu

re

• Al-deficit alloy 稀铝合金

• Minimize the secondary phases in the BCC matrix避免在BCC组织中的析出物

• Consider coherent secondary phases 共格第二相

• High melting point 高熔点

31

STORYLINE 叙事线

▪ALLOY DESIGN 合金设计

▪RECYCLED METAL – SECONDARY AL 金属回收－二次铝合金

▪MEASURES AND CONTROLS - Molten Metal 熔融金属的成分测量和质量控制

▪MEASURES AND CONTROLS - - Cast Product 铸造产品的成分测量和质量控制

▪PROCESS COGNITION 生产过程交互识别

32

350 lbs. (2012)

547 lbs.

(2025)

Po

un

ds p

er

Veh

icle

(P

PV

)

YearSource: Ducker Worldwide

Al Penetration- Vehicles 铝在汽车中的渗透

33

占重比例

34

SECONDARY ALUMINUM

… not a second class product!二次铝合金

…不是（二）次等的产品!

Shredding

&

Magnetic Separation Mix with other end of life

scrap streams

Ferrous

Non-

ferrous

• Zurik

• ICW/IAW

• Fe - Al

Zorba

Twitch

Zebra

End of life vehicle (ELV)

Downstream

Separation

Systems

Separation systems:

-Air separation

-Eddy-current

-Induction sorters

-Density (media-based)

-Intelligent sorting

systems – XRT, XRF,

LIBS

Zorba: ~65% Al alloy, Cu alloys, Mg, Zn,

stainless steels, brass, organics, etc. [1]

Twitch: light Zorba fraction, 90-98% Al alloy,

some Mg, Fe/steel (screws, bolts), organics [1]

Zebra: heavy Zorba fractions, Cu, Zn, brass,

stainless steel [1]

Dismantling/

Fluid draining

Retail part/scrap

sale

Flattened auto-hulk

Twitch: exported or used to form secondary 380/319 in the US

Background: ELV Recycling - Auto-Al

35

Twitch Processor Si Fe Cu Mn Mg Zn

Site A 3.8 ± 0.75% 0.62 ± 0.11% 1.2 ± 0.34% 0.22 ± 0.05% 1.9 ± 1.2% 0.95 ± 0.38%

Site B 4.8 ± 0.94% 0.68 ± 0.06% 1.4 ± 0.36% 0.23 ± 0.05% 1.9 ± 0.54% 1.0 ± 0.41%

319 5.5 - 6.5% 0 - 1% 3 - 4% 0 - 0.5% 0 - 1% 0 - 1%

380 7.5 - 9.5% 0 - 2% 2 - 4% 0 - 0.5% 0 - 1% 0 - 3%

Significant

amount of

alloying required 需要大量增加的合金元素

Significant

amount of

demaggingrequired需要大量减少合金元素

- Challenge the use of Twitch to only produce secondary 380 and 319 生产二次380、319合金的难点：

Why is Twitch downcycled? 为何是降级回收?… Limited knowledge regarding its “DNA” 因为对于它的”DNA”信息知之甚少。

A changing landscape….

模式的改变

Background背景: Current State 现状

36

Scrap Al Export from US

Background背景: A Changing Landscape 正在改变的模式

EVs lower secondary cast demand, increase aluminum

sheet demand

• 25 – 27% more sheet aluminum

• No demand for engine cast alloys

Ford F150

Aluminum Intensive Vehicles [5]

Tesla Model 3

Electric Vehicles [6]

• 45 – 70% of the aluminum scrap generated in the US has

been exported to China since 2002 annually

• 2011 – 2015: ~28% decrease

International Trade [2-4]

US → China

Cast vs. Wrought Consumption:

2002: ~80% cast – 20% wrought

2028: ~40% cast – 60% wrought

350 lbs.

(2012)

547 lbs.

(2025)

Po

un

ds

pe

r V

eh

icle

(P

PV

)

Year

How should this added aluminum

be recovered and recycled?

这些铝合金产业的新变化如何对回收业产生影响？

What do the material collectors,

processors and consumers need

to know to up-cycle Al scrap?

为何材料的开采方，处理方，和消费端需要了解铝合金废料生产

的上游端？37

Intelligent Sorting System (ISS)

智能分类系统

Targeted

Scrap

- Sorting criteria

designed for a specific

property or composition

Ejected

Scrap

- Particulate identified to

match sorting criteria Rejected

Scrap

- Particulate that does not match

any sorting criteria

X-ray transmission (XRT)

Laser-induced breakdown

spec. (LIBS)

X-ray fluorescence (XRF)

38

Background 背景: Intelligent Sorting Systems 智能分类系统

Objective: Use more auto-shred in alloy production

目标：利用一定比例的多种合金制成新合金

Resource A Resource B … Resource n Alloy 1

成本Cost…

成分Composition…

获取的难易程度Availability…

成分Composition…

需求Demand…

39

Blending Model 混合模式

▪ UPGRADE SCRAP升级废料

▪ MAKE WASTE A PRODUCT把废品变为产品

▪ REUSE再生使用

Strategy: CREATE VALUE FROM WASTE策略：变废为宝

TAKE AWAY MESSAGE

STORYLINE 叙事线

▪ALLOY DESIGN 合金设计

▪RECYCLED METAL – SECONDARY AL 金属回收－二次铝合金

▪MEASURES AND CONTROLS - Molten Metal 熔融金属的成分测量和质量控制

▪MEASURES AND CONTROLS - - Cast Product 铸造产品的成分测量和质量控制

▪PROCESS COGNITION 生产过程交互识别

42

Al Integrated MiniMill - AIM

US Patent 9,9956,6092 Provisionals - WPI

MELT COGNITION LLC

LIBS TECHNOLOGY

Distributed and Serviced by ALTEK

MELT COGNITION LLC

STORYLINE 叙事线

▪ALLOY DESIGN 合金设计

▪RECYCLED METAL – SECONDARY AL 金属回收－二次铝合金

▪MEASURES AND CONTROLS - Molten Metal 熔融金属的成分测量和质量控制

▪MEASURES AND CONTROLS - - Cast Product 铸造产品的成分测量和质量控制

▪PROCESS COGNITION 生产过程交互识别

45

Computed tomography (CT) set up断层扫描系统配置

Image Acquisition图像采集

Three basic components

▪ X-ray tube 射线管

▪ Detector 探测器

▪ Manipulator 操纵部件

CT System DesignCT系统的设计

Evolution of Quality Control质量检测的进化史

Autonomous Inspection Solutions (AIS)自动化监测方案

Load Part Part ID Barcoding Load Profile

Inspect PartCharacterize

Unload Part

STORYLINE 叙事线

▪ALLOY DESIGN 合金设计

▪RECYCLED METAL – SECONDARY AL 金属回收－二次铝合金

▪MEASURES AND CONTROLS - Molten Metal 熔融金属的成分测量和质量控制

▪MEASURES AND CONTROLS - - Cast Product 铸造产品的成分测量和质量控制

▪PROCESS KNOWLEDGE AND CONTRL 工艺知识与控制

51

Machine Learning and Manufacturing 机器学习与制造业

https://iiot-world.com/connected-industry/what-data-science-actually-means-to-manufacturing/

But, what is it...Artifical Intelligence vs. Machine Learning 人工智能vs机器学习

https://blogs.nvidia.com/blog/2016/07/29/whats-difference-artificial-intelligence-machine-learning-deep-learning-ai/

Dog

( ; )f x y =

Cat

????

https://www.flickr.com/photos/mwichary/4358926764

( ; )f x y =

https://www.google.com/imgres?imgurl=http%3A%2F%2Fberntsen-foundry.com%2Fwp-content%2Fuploads%2F2016%2F01%2FIMG_46201-e1453743190857.jpg&imgrefurl=http%3A%2F%2Fberntsen-foundry.com%2Fporosity-free-aluminum-castings%2F&docid=z1HO4tJ1gH1SuM&tbnid=wEb4F-MWNBvuXM%3A&vet=10ahUKEwi0h5Om1ZbiAhXJmq0KHfXfDQ0QMwg8KAAwAA..i&w=575&h=201&bih=842&biw=1268&q=porosity%20in%20casting&ved=0ahUKEwi0h5Om1ZbiAhXJmq0KHfXfDQ0QMwg8KAAwAA&iact=mrc&uact=8

( ; )f x y =

https://www.google.com/imgres?imgurl=http%3A%2F%2Fberntsen-foundry.com%2Fwp-content%2Fuploads%2F2016%2F01%2FIMG_46201-e1453743190857.jpg&imgrefurl=http%3A%2F%2Fberntsen-foundry.com%2Fporosity-free-aluminum-castings%2F&docid=z1HO4tJ1gH1SuM&tbnid=wEb4F-MWNBvuXM%3A&vet=10ahUKEwi0h5Om1ZbiAhXJmq0KHfXfDQ0QMwg8KAAwAA..i&w=575&h=201&bih=842&biw=1268&q=porosity%20in%20casting&ved=0ahUKEwi0h5Om1ZbiAhXJmq0KHfXfDQ0QMwg8KAAwAA&iact=mrc&uact=8

High dimensional data and Principal Component Analysis 高维数据与主成分分析

Principal Component Analysis is an automated way to think about distances

主成分分析能自动分析数据之间的”距离”

http://setosa.io/ev/principal-component-analysis/

http://setosa.io/ev/principal-component-analysis/

What make manufacturing data different制造业数据的特点 (and an interesting project for a Data Science Ph.D. 作为数据科学的博士论文项目)?

• Manufacturing data can be:1. Unbalanced 不平衡 – There are many “good” parts

and perhaps just a few “bad” parts.大量样品是合格的，只有少数不合格。

2. Semi-supervised 半监督– Sometimes telling if a part is “good” or “bad” involves a destructive test.判断样品是否合格需要无损检测。

3. Heterogeneous 异质性– Not every part many have the same measurements. E.g., you may X-ray some parts, but it is too expensive to test them all. 并非所有样品都需要做检测。比如：我们可以仅仅检测部分样品的X-射线，如果全部检测会造成成本过高。

BRIGHT FUTURE FOR LIGHT METALS AND FOUNDRY INDUSTRY

轻金属材料与铸造业的前景光明

59

CHALLENGES

▪ FUTURE OF WORK/ FUTURE OF THE WORKER未来的任务／完成任务的人

▪ RECOVERY, REUSE, AND REDUCE WASTE回收，再利用，与减少废品

▪ DEMATERIALIZE材料虚拟化

THANK YOU. GRACIAS. SHOUKRAN-شكر. MERCI. TAK TAK. AFKHARISTO-ευχαριστίες. GRAZIE. DANKE. ARIGATO-

感謝. XIE XIE-谢谢 . MAHALO. СПАСИБО-SPASIBO. DANK U. DHANYAVAAD धन्यवाद.

SHNORHAGAL YEM ՇՆՈՐՀԱԿԱԼ ԵՄ

MAM’NOON ممنون

dapelian@wpi.edu

dapelian@uci.edu