ICME Gap Analysis: Structural Materials for Automotive Applications: High-Temperature Alloys 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 8:30 AM
February 27, 2017
Room: 10
Location: San Diego Convention Ctr

Session Chair: Jerry Gibbs, Department of Energy; Dognwon Shin, Oak Ridge National Laboratory

8:30 AM  Invited
Bridging the Gap between ICME Design and Implementation of Third Generation Advanced High Strength Steels for Automotive Applications: Louis Hector Jr1; Anil Sachdev1; Tyson Brown1; 1General Motors
    Integrated computational materials engineering (ICME) has the potential to accelerate the design of third generation advanced high strength steels and their subsequent implementation into vehicle architectures. However, bridging the gap between ICME prediction of the new steels and their development and application remains a significant challenge. The gap has three major components: (1) experimentally-validated computations that capture and integrate the complex multi-scale microstructural behavior in these multiphase materials under different strain paths and loading rates to predict the desired microstructures; (2) scale-up of these ICME-predicted microstructures within the composition and processing constraints of the steel producers; and (3) use of these steels relative to manufacturing challenges and product performance requirements. Selected aspects of each gap category will be discussed with special emphasis on the influence of microstructure and phase transformation at the multiple length scales.

9:10 AM  Cancelled
Application of ICME in the Development of Cast Steel Alloys: Rick Huff1; Caian Qiu1; Adrian Catalina1; 1Caterpillar
    The development and insertion of new cast alloys and processes in industrial applications is traditionally very time consuming and expensive. Lack of production and field history of new alloys often makes the risk too high to quickly implement into critical components. The grand vision of fully implemented ICME offers a means to greatly accelerate new alloy development and implementation into new and improved products. This presentation will discuss the application of ICME at Caterpillar to optimize cast steel alloys and processes for a variety of product applications. Commercial and internally developed computational tools are applied to model the material behavior across the processing chain. The formation of grain boundary phases due to segregation and micro-porosity and inclusion defects have a strong impact on actual measured mechanical properties, but such impact is not easily accounted for in model predictions. Several gaps to achieving the full ICME vision will be highlighted.

9:50 AM Break

10:05 AM  Invited
ICME Model Development and Gap Analysis for Advanced Cast Aluminum and Magnesium Alloys for Automotive Applications: Mei Li1; 1Ford Motor Company
    Recently legislated fuel economy standards require new U.S. passenger vehicles to achieve at least 58 MPG by 2030, up from 28.8 MPG today. Two major methods of achieving improved fuel economy in passenger vehicles are reducing the weight of the vehicle and developing high-performance engines. To reduce the weight of the vehicle advanced cast aluminum and magnesium alloys are being increasingly used in both automotive powertrain and body applications. To increase engine efficiency, the maximum operation temperature of these components has increased from approximately 170C in earlier engines to peak temperatures well above 200C in recent engines. The increase in the operational temperatures requires a material with optimized properties in terms of tensile, fatigue and thermos-mechanical fatigue strength. ICME models play an important role in accelerating the development of new alloys, design and optimization of the performance of the components. This talk will present two examples which demonstrate the recent development of ICME models at Ford for advanced cast aluminum and magnesium alloy applications, and identify the gaps in meeting the challenging requirements in ICME approach.

10:45 AM  Invited
Progress and Gaps in Thermodynamic Modeling for the Development of Advanced Cast Aluminum Alloys using Integrated Computational Materials Engineering: Mike Walker1; Andrew Bobel2; WeiWei Zhang3; Nick Hatcher3; Abhinav Saboo3; Dana Frankel3; Kyoungdoc Kim2; Christopher Wolverton2; 1General Motors; 2Northwestern University; 3QuesTek Innovations, LLC
    For the development of improved alloys using ICME, the thermodynamic databases must accurately reflect the potential contribution of both the major and minor elements on the phase stability and solid solution strengthening in the alloy. The common precipitate phases in aluminum alloys such as the theta phase, the beta phase, and the Q phase have been well documented in the literature. However, thermodynamic databases do not accurately reflect solubility limits and phase boundaries or the contribution of minor elements. High-throughput DFT calculations have identified new phases, however the lack of a full thermodynamic description of novel phases makes it difficult to predict their stability. This talk will highlight advances in thermodynamic databases with an emphasis on a re-calibration of the Q-phase and a review of remaining discrepancies and gaps in aluminum alloy descriptions. Finally, the challenges in predicting the effects of minor elements on phase stability will be reviewed.

11:25 AM  Invited
An Assessment of Modeling Tools for High Temperature Aluminum Alloy Development: The Good, the Bad and the Ugly: Amit Shyam1; Dongwon Shin1; Shibayan Roy1; Adrian Sabau1; Yukinori Yamamoto1; James Haynes1; 1Oak Ridge National Laboratory
    The Integrated Computational Materials Engineering (ICME) approach promises to accelerate the development of new materials such as high temperature cast aluminum alloys for passenger car engines. New alloys for complex applications such as engines, however, need to satisfy a variety of properties that cannot be improved simultaneously. Development and application of models can help perform the tradeoffs that are necessary for new alloy development. All models, however, are not equivalent in their degree of maturity. An assessment of the current state of the art and gaps will be presented for high temperature cast aluminum alloys in relation to: (a) mechanical and thermophysical properties, (b) thermodynamic and kinetic prediction tools, (c) casting and related phenomena, (d) alloy design tools and (e) other relevant properties such as corrosion. A report card of the efficacy of the modeling tools will be provided along with recommendations for future investment by government agencies.