A novel approach to the design and optimisation of aluminium cast component heat treatment processes using advanced UMSA physical simulations

Abstract

Purpose: The goal of this publication is to present a new laboratory methodology for simulation of industrial melting, solidification and heat treatment using the patented Universal Metallurgical Simulator and Analyzer (UMSA) Technology Platform [10]. Two examples to demonstrate UMSA’s capabilities are presented for optimized heat treatment processes at the request of the North American automotive industry. Design/methodology/approach: The unique UMSA Platform was used to rapidly physically simulate very complex industrial heat treatment processes using stationary macro test samples and computer controlled heating and cooling source. Findings: The UMSA simulations proved to be very accurate in order to simulate the non-linear temperature/ time profile of the solidification process combined with the continuous heat treatment operation. Moreover, the complex industrial heat treatment process was successfully replicated for an 800g test sample and the targeted structural and mechanical properties were met. Research limitations/implications: Selected examples of the heat treatment have been presented for aluminum based alloys only. The current research addresses Mg and Ti based alloys and thermal processing under vacuum and inert/active environments. Practical implications: The presented methodology is capable of dissecting all processes and linking the cast component’s optimized performance with individual production steps. The technical capabilities of the UMSA Platform have been recognized and have already been applied by industrial partners. Originality/value: The simulation method that is presented here will greatly improve the ability of laboratory investigators to simulate and assess the effects of the heat treatment variables.