Abstract Scope |
Magna International utilized Integrated Computational Materials Engineering (ICME) to develop Aural 5M, a modified primary aluminum alloy designed for structural automotive components. Through a combination of theoretical modeling and experimental validation, Thermo-Calc and JMatPro software’s were used to predict phase stability, enhance castability, and improve manufacturability while eliminating heat treatment to reduce environmental impact. Experimental results demonstrated that Aural 5M exhibited superior castability and lower porosity compared to the baseline Aural 5S. This research accelerated the development of next-generation secondary Aural R alloys, which incorporate 100% recycled content with increased levels of iron, copper, and zinc for enhanced sustainability. The evolution of Aural 5R highlights its potential for broad automotive applications and facilitates technology transfer across the industry. ICME’s integration of materials data with performance and manufacturing simulations significantly reduced development time, underscoring its role in advancing innovation, optimizing material properties, and promoting sustainable practices in automotive alloy design. |