Development of advanced materials and manufacturing processes for the production of lighter car bodies and electric motors

The purpose of this project is to investigate the innovative near-net and net shape casting capabilities of the Horizontal Single Belt Casting (HSBC) technique. Three specific objectives of great interest for Quebec and in particular for the automotive industry are targeted, specifically, the production of : - Very thin sheets (150 µm) that would serve as starting material for soft magnetic laminated composites extremely useful for the armature of electric motors in vehicles. - thin (~1-2mm) aluminium alloy sheets for car bodywork for weight reduction. - high strength, high ductility steel sheets (~1-5mm) for car parts to increase impact resistance and reduce vehicle weight. The achievement of these objectives will resolutely demonstrate that the Horizontal Single Belt Casting (HSBC) process is ideal and the only reasonable Near Net Shape Casting process capable of producing thin and extra thin steel and aluminium sheet. The investment and operational costs of near net shape casting and in particular Horizontal Single Belt Casting (HSBC) for thin metal strips are about one sixth of the costs of conventional slab casting, rolling and heat treatment operations. At the same time, NNSC for thin automotive body tapes is a low-emission process that produces five times less greenhouse gases. In addition, innovative research into the promotion of electric cars in Quebec is an integral part of the present project.

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