Center for Advanced Vehicular Systems

Spotlight on Research - Powder-Metal Performance Modeling of Automotive Components

To evaluate the insertion of various lightweight materials in future component applications, math-based models for Powder Metallurgy (P/M) component design and performance prediction are developed and experimentally validated. The transition of current materials/design requirements to advanced structural P/M components has created a need to predict the properties of components in all sections of design. An existing math-based framework is extended with the abilities to predict P/M component structures and properties accurately throughout the compaction and sintering processes such as section size, density variation, dimensional tolerances, and potential for cracking; and with the input of alloys and process parameters such as machine functions, tool and powder temperatures, friction and pressure.

The history of a P/M part is captured through its pressing, sintering, and life-cycle performance using a developed multiscale methodology. In addition, design optimization of and statistical techniques are used to consider least cost, lowest mass product designs and reduced development lead-time, and to help determine the main factors affecting the final component. Finally, the model is used to evaluate and optimize the component design of a main bearing cap as affected by materials and compaction and sintering processes.