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LIGHTWEIGHT METALLIC MATERIALS FOR AUTOMOBILE AND
ENGINEERING APPLICATIONS
Speaker: S.Das
Report Submitted by Pavan R Mutalikdesai (211ME1345)

Objective:
It deals with the development of energy efficient metallic materials with improved characteristics for
different engineering applications.
The main research areas of the seminar are
1) Lightweight Materials -
Foams, Mg Alloys, MMCs,
Polymer Composites
2) Smart Materials
Cu, Al, Fe SMAs
Shape Memory Polymers
3) Nano Materials
Nano Materials for Engineering Applications
Introduction:
Metal foam is a cellular structure consisting of a solid metal, frequently aluminum, containing a large
volume fraction of gas-filled pores. The pores can be sealed (closed-cell foam), or they can form an
interconnected network (open-cell foam). Metallic foams typically retain some physical properties of their
base material. Foam made from non-flammable metal will remain non-flammable and the foam is
generally recyclable back to its base material. Coefficient of thermal expansion will also remain similar
while thermal conductivity will likely be reduced. Usually open cell Al foam is produced by infiltration of
polyurethane foam with heat resistant material. The polyurethane foam is subsequently removed by
heating and liquid metal is infiltrated through the fine pore. AMPRI has developed a novel technique to
produce open cell Al foam using melt route.
Magnesium alloys are mixtures of magnesium with other metals (called an alloy), often aluminum,
zinc, manganese, silicon, copper, rare earths and zirconium. Magnesium is the lightest structural metal.
Magnesium alloys have a hexagonal lattice structure, which affects the fundamental properties of these
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alloys. Therefore magnesium alloys are typically used as cast alloys, but research of wrought alloys has
been more extensive since 2003. Cast magnesium alloys are used for many components of modern cars,
and magnesium block engines have been used in some high-performance vehicles; die-cast magnesium is
also used for camera bodies and components in lenses.
A metal matrix composite (MMC) is composite material with at least two constituent parts, one being
a metal. The other material may be a different metal or another material, such as a ceramic or organic
compound. When at least three materials are present, it is called a hybrid composite. An MMC is
complementary to a cermet. MMCs are made by dispersing a reinforcing material into a metal matrix. The
reinforcement surface can be coated to prevent a chemical reaction with the matrix.
For example, carbon fibers are commonly used in aluminum matrix to synthesize composites showing
low density and high strength.MMC manufacturing can be broken into three types: solid, liquid, and
vapor.
Solid state methods include powder blending and consolidation.
Liquid state method includes squeeze casting and spray deposition technique.
Vapour deposition technique also includes In situ process.
Smart materials or designed materials are materials that have one or more properties that can be
significantly changed in a controlled fashion by external stimuli, such as stress, temperature, moisture,
pH, electric or magnetic fields. For example, piezoelectric materials are materials that produce a voltage
when stress is applied. Since this effect also applies in the reverse manner, a voltage across the sample
will produce stress within the sample. Suitably designed structures made from these materials can
therefore be made that bend, expand or contract when a voltage is applied.
Nanomaterials are a field that takes a materials science-based approach to nanotechnology. It studies
materials with morphological features on the nanoscale, and especially those that have special properties
stemming from their nanoscale dimensions. Nanoscale is usually defined as smaller than a one tenth of a
micrometer in at least one dimension, though this term is sometimes used for even smaller materials.


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Applications:
Metallic foams are currently being looked at as a new material for automobiles. The main goal of the use
of metallic foams in vehicles is to increase sound dampening, reduce the weight of the automobile, and
increase energy absorption in case of crashes, or in military applications, to combat the concussive force
of IEDs.
Wheels were one of the first applications for Mg, and development of a competitive production process
based on welded extruded and/or stamped components could enable wide use. Some racing cars
(Mercedes 300SL, Porsche 962) had the frame and skin made from magnesium.Drive brackets, oil pan,
steering column brackets, 4-wheel drive transfer case, manual transmission case, induction cover, clutch
pedal, brake pedal, steering column brackets, crankcase, chain housing, steering box, rear-link arms, sub
frame.
Some automotive disc brakes use MMCs, The MMC driveshaft has become a common modification for
racers, allowing the top speed to be increased far beyond the safe operating speeds of a standard
aluminum driveshaft. Honda has used aluminum metal matrix composite cylinder liners in some of their
engines, Carbide drills are often made from a tough cobalt matrix with hard tungsten carbide particles
inside.
Conclusion-
The aim of the seminar is to work with consortium mode with CSIR Laboratories along with
academic Institutes and Industries to develop energy effective Application oriented
materials/processes/Components for automobile and related applications. Identification of
user/manufacturing industries and interaction with them is considered as the major activities
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