ICME Gap Analysis: Structural Materials for Automotive Applications: Light-weight Materials for Automotive Applications
Sponsored by: TMS Materials Processing and Manufacturing Division, TMS: Integrated Computational Materials Engineering Committee
Program Organizers: Dongwon Shin, Oak Ridge National Laboratory; Jerry Gibbs, Department of Energy; Will Joost, Department of Energy; Nicholas Hatcher, QuesTek Innovations, LLC

Monday 2:00 PM
February 27, 2017
Room: 10
Location: San Diego Convention Ctr

Session Chair: Will Joost, Department of Energy; Nick Hatcher, QuesTek Innovations, LLC

2:00 PM  Invited
The Phase Field Method and Materials Design: K. Kim1; M.P. Guruajan1; C. Wolverton1; Peter Voorhees1; 1Northwestern University
    Phase field methods can provide new insights into the factors controlling the shape, composition, and spatial arrangement of precipitates in solids and dendrites in a liquid. The advantage of the phase field method is that it is not necessary to track the location of the interface between two phases, since all the fields are continuous. This presents a computational challenge given the large length scale mismatch between the width of the interface between two phases and the size-scale of typical microstructures. We illustrate the challenge by examining the morphologies of theta’ precipitates in an Al-Cu alloy. We account for the faceted interfaces of the precipitate, differences in elastic constants between the precipitate and matrix, and anisotropic elastic constants. In view of the computational constraints imposed by the phase field method, the prospects for using it in an iterative materials design effort will be discussed.

2:40 PM  Invited
Case Studies and Gap Analyses in ICME for Structural Materials in Automotive Applications: Xin Sun1; 1Pacific Northwest National Laboratory
    Integrated Computational Materials Engineering (ICME) was described by the National Research Council Report (2008) as the ‘integration of materials information, captured in computational tools, with engineering product performance analysis and manufacturing-process simulation’. The purpose of ICME is for product-level material’s engineering, its means is through computational tools and its key word is ‘integrated’. Structural materials ICME demands the integration of physics-based materials models at different scales simulating different materials processing conditions, with experimental validation, hence provides the predictive capability for cost-effective process scale up and rapid engineering deployment. Although there have been several ICME success stories in the automotive industry, technological gaps still existing in explicit integration of models at different scales and for different physical processes. In this talk, two case studies on ICME of advanced high strength steels and Mg castings will be used to illustrate the communities progress to date and gaps in ICME for structural materials.

3:20 PM Break

3:35 PM  Invited
ICME for Automotive Composites – Development of Predictive Integrated Stochastic Manufacturing and Structural Performance Models: Venkat Aitharaju1; 1General Motors
    ICME of automotive materials has been an active area of research in the past few years. There has been some progress and success stories, but several unresolved issues especially in the case of composites, continues to prohibit the usage of these developments in commercial industrial simulations. To meet the 54.5 mpg CAFE requirement through lightweighting, among other options, GM is interested in evaluating carbon fiber composites in body structural panels that have to meet complex loading requirements for crash and durability. Since the technology to validate the automotive composite material designs for these structural areas is not currently available, GM has teamed up with leading composite material simulation software companies and academia through a Department of Energy funded project to develop a state of the art probabilistic ICME tools to realize the knowledge base. In this paper, the progress of the project in the last two years will be presented.

4:15 PM  Invited
Integrated Computational Materials Engineering for Automotive Light Metals: Alan Luo1; 1The Ohio State University
    Advanced light metals (aluminum, magnesium and titanium alloys) are increasingly being used in the automotive industry for weight reduction and structural efficiency. Integrated Computational Materials Engineering (ICME) is defined as the integration of materials information, captured in computational tools, with engineering product performance analysis and manufacturing-process simulation. ICME involves development of unified materials models which integrate information across length and time scales and across knowledge domains and enables integration of simulations of manufacturing, design and materials into a holistic system. ICME offers a solution to quickly develop engineering products at the lowest possible mass/costs. This talk will highlight some of the progress made and identify gaps in using ICME tools to develop light alloys, manufacturing processes and components for automotive structural applications.

4:55 PM  Invited
Limitation of the ICME Approach for Mg Alloy Production via Twin Roll Casting Process: In-Ho Jung1; 1McGill University
    Twin roll casting (TRC) process is the most cost competitive casting process to produce wrought Mg alloys. As TRC process involves both casting and rolling of thin strip, there is a certain limitation for the choice of Mg alloys to be produced via this process. At the moment, this process is successfully applied to the production of limited AZ series Mg alloys with low Al content. There has been great interest in the development of new wrought Mg alloys suitable for TRC process for automotive applications. In this presentation, the TRC process will be firstly reviewed, and the TRC Mg alloy design concept will be presented. In particular, the current gap of the ICME approach for the development of new Mg alloy suitable for the TRC process will be discussed.