{"id":27930,"date":"2015-02-20T00:00:00","date_gmt":"2015-02-20T05:00:00","guid":{"rendered":"http:\/\/ashleydev.com\/2015\/02\/20\/applying-nuclear-expertise-to-solve-the-auto-industrys-challenges\/"},"modified":"2020-08-27T11:41:09","modified_gmt":"2020-08-27T15:41:09","slug":"applying-nuclear-expertise-to-solve-the-auto-industrys-challenges","status":"publish","type":"post","link":"https:\/\/cna.ca\/fr\/2015\/02\/20\/applying-nuclear-expertise-to-solve-the-auto-industrys-challenges\/","title":{"rendered":"Applying Nuclear Expertise to Solve the Auto Industry’s Challenges"},"content":{"rendered":"

This article was originally printed in the Winter\/Spring 2015 edition of Lead, Reach and Connect, which is published twice per year for the Automotive Parts Manufacturers\u2019 Association (APMA). It has been reprinted with permission from the APMA and Matrix Group Publishing Inc. and cannot be reproduced without prior written consent. To view the full edition of the magazine, please go to https:\/\/apma.ca\/news\/publish\/finallowresapmawinterspring15websitepdf#content-head<\/a>.<\/p>\n

By Clemente Angiolillo and Daniel Banks<\/strong><\/p>\n

\"neutron

The neutron beamlines at the National\u00a0Research Universal (NRU) reactor\u00a0protrude out from the shielding wall\u00a0around the reactor to allow materials\u00a0to be analyzed non-destructively in the\u00a0beams.<\/p><\/div>\n

Situated two hours northwest of the nation\u2019s capital on the scenic shores of the Ottawa\u00a0River, Canadian Nuclear Laboratories (CNL), Canada\u2019s national nuclear science and\u00a0technology organization, has been a key player in the global nuclear sector from its\u00a0inception over 60 years ago. Through the work done at Chalk River Laboratories,\u00a0CNL gave the world a uniquely Canadian reactor design known as CANDU, and\u00a0put forth pioneering innovations in the area of nuclear medicine and environmental\u00a0remediation technologies, just to name a few areas of expertise.<\/p>\n

However, as several auto parts suppliers will attest, the solutions offered by nuclear\u00a0technologies have application in other industries as well. Today, as the auto industry\u00a0grapples with many technical challenges to meet stringent fuel efficiency targets\u2014\u00a0achieved partly by obtaining favourable strength-to-weight ratios for motor vehicles\u2014\u00a0as well as enhancing quality assurance of parts and components, researchers at CNL\u00a0are bringing their unique facilities and expertise to the auto industry\u2019s doorsteps, and\u00a0with remarkable results.<\/p>\n

\"in-situ

A visiting researcher prepares an\u00a0advanced in-situ examination of\u00a0an alloy\u2019s properties under various\u00a0conditions of applied load on a neutron\u00a0beamline.<\/p><\/div>\n

\u201cOn the heels of CNL\u2019s participation at the Automotive Parts Manufacturers\u2019\u00a0Association (APMA) Annual Conference & Exhibition held in Windsor, ON in early\u00a0June, we were pleased to announce that we had secured a new customer named AGS\u00a0Automotive Systems Inc. to perform metallographic and surface analysis of various\u00a0chrome plated parts,\u201d says Elliott Gillespie,\u00a0CNL director of marketing and international\u00a0business.<\/p>\n

The recently appointed marketing\u00a0director says the technical challenge of\u00a0this commercial contract is to perform indepth\u00a0studies on the components to locate\u00a0potential particulate or contaminants residing\u00a0between very thin material plating layers,\u00a0thus ensuring optimization of longterm\u00a0corrosion resistance once the parts\u00a0are placed in extreme weather conditions.\u00a0AGS Automotive is a Tier 1 automotive parts\u00a0supplier (and APMA member) specializing\u00a0in bumper impact assemblies with capabilities\u00a0in metal stamping, chrome-plating,\u00a0Class A painting and welding. The company\u00a0operates 10 facilities in North America and\u00a0has approximately one-third of the chromeplated\u00a0bumper business\u2014producing mainly\u00a0front and rear impact system assemblies and\u00a0modules, as well as some general stampings,\u00a0running boards and exterior painted\u00a0trim parts such as grills\u2014as sister company\u00a0Tiercon Corp. Customers include GM, Toyota,\u00a0Chrysler, Volkswagen and other major\u00a0original equipment makers.<\/p>\n

Years of automotive research\u00a0<\/strong><\/p>\n

\"new

A visiting researcher makes small\u00a0adjustments to the positioning of a new\u00a0alloy sample on a neutron beamline to\u00a0map its properties in three dimensions.<\/p><\/div>\n

Lest one get the impression that CNL\u2019s\u00a0work in the automotive parts sector is a\u00a0recent business activity, think again. Years\u00a0of research on technologies to make lightweight\u00a0car engines reliably have been afoot\u00a0at Chalk River and may soon pay off with\u00a0big dividends to parts suppliers. In addition,\u00a0the value of CNL\u2019s contributions to these technologies are being recognized by peer\u00a0organizations and partners such as the Canadian\u00a0Academy of Engineering (CAE), who\u00a0recently bestowed a CNL researcher with a\u00a0prestigious honour.<\/p>\n

Dr. Dimitry Sediako, a Senior Research\u00a0Officer, was inducted as a Fellow of the CAE\u00a0in June 2014 in recognition of his contributions\u00a0to improving manufacturing technologies\u00a0in engine block casting and heat treatment,\u00a0among other achievements. According\u00a0to CNL customer Nemak Canada, these\u00a0technologies, when implemented, will speed\u00a0production times and reduce energy usage,\u00a0thereby saving millions in manufacturing\u00a0costs.<\/p>\n

Some of these achievements and applications\u00a0strike automotive manufacturers as\u00a0novel and have potential customers wondering\u00a0how exactly nuclear technologies can\u00a0deliver value to the auto parts sector. Part\u00a0of the formula for success is having diverse\u00a0supporting facilities and the right expertise,\u00a0but the other important piece is direct access\u00a0to industry partners. And then there is the\u00a0power of neutrons.<\/p>\n

The power of neutrons<\/strong><\/p>\n

CNL hosts the only major neutron beam\u00a0laboratory in Canada at its multipurpose\u00a0National Research Universal reactor. Neutron\u00a0beams, like no other tool, can be used to\u00a0non-destructively probe deep inside engine\u00a0blocks and determine the amount of stress\u00a0in the material at any given point, which is\u00a0a key factor in the reliability of the engine.\u00a0Having honed this capability for decades,\u00a0CNL\u2019s researchers are world leaders in using\u00a0neutron beams to determine properties of\u00a0metallic materials, and have examined parts\u00a0for jet engines, car engines, ship hulls, pipelines,\u00a0bridges, and rail tracks, in addition to\u00a0parts for nuclear reactors.<\/p>\n

\"Dr.

Researcher Dr. Dimitry Sediako sets\u00a0up an engine block for non-destructive\u00a0examination of residual stress on a\u00a0neutron beamline at the National\u00a0Research Universal (NRU) reactor at\u00a0Canadian Nuclear Laboratories (CNL).<\/p><\/div>\n

Although not yet standardized in the\u00a0automotive industry, leading companies are\u00a0now beginning to make use of this hightech\u00a0tool. Dr. Sediako has built partnerships\u00a0with researchers from Nemak Canada, major\u00a0automotive manufacturers such as General\u00a0Motors (GM) and Ford Motor Company,\u00a0four universities (Ryerson University, University\u00a0of British Columbia, University of\u00a0Waterloo, McGill University), and Canmet\u00a0Materials Laboratory, each of which contributed\u00a0their own tools and expertise in\u00a0metallurgy, mechanical testing and computer\u00a0modelling.<\/p>\n

In one line of research, Nemak\u2019s objective\u00a0was to find the best way to build\u00a0robust V-6 aluminum engine blocks.\u00a0These engines have extremely low tolerance\u00a0for distortion in the shape of the\u00a0cylinder holes in the block. Stress relief\u00a0methods are used after casting the block\u00a0to increase stability, and yet each manufacturing\u00a0step comes with its own costs\u00a0and impacts on the materials properties. To\u00a0improve over current manufacturing practices,\u00a0the team needed to understand more\u00a0clearly the factors contributing to stability.<\/p>\n

Nemak and its research partners from\u00a0Ryerson University accessed Chalk River\u2019s\u00a0neutron beams for several studies with Dr.\u00a0Sediako\u2019s assistance to acquire and interpret\u00a0the neutron diffraction data. These studies\u00a0included elucidating the stress distribution\u00a0and microstructure in new aluminum alloys\u00a0and in engine blocks, before and after stress\u00a0relief methods such as heat treatment. Additionally,\u00a0they included pioneering observations\u00a0of microstructural evolution during\u00a0solidification of the alloys.<\/p>\n

The results were vital contributions to\u00a0the success of the research, helping Nemak\u00a0to determine that simplifying the heat treatment\u00a0process is feasible without compromising\u00a0reliability. Nemak is now moving forward\u00a0to validate the new process by performing\u00a0final tests before the engine can be used in\u00a0vehicles sold to customers, such as putting a\u00a0prototype engine block in a test vehicle.<\/p>\n

Neutrons help GM<\/strong><\/p>\n

During a recent webinar organized in\u00a0conjunction with APMA, CNL worked with\u00a0Nemak and GM to showcase the application\u00a0of nuclear technology to develop better\u00a0engine components, and elaborate on the\u00a0range of nuclear capabilities available to automotive\u00a0companies through CNL.<\/p>\n

GM uses neutron beams to accelerate the\u00a0development of engine heads and blocks.\u00a0These projects span three primary research\u00a0areas:<\/p>\n

\u2022 Evaluating effectiveness of heat treatment\u00a0and quenching methods.
\n\u2022 Directly observing phase precipitation\u00a0during solidification.
\n\u2022 Creep testing to make better predictions\u00a0of reliability over the long-term.<\/p>\n

In the first area of evaluating effectiveness\u00a0of heat treatment and quenching methods,\u00a0neutron experiments clearly falsified\u00a0a hypothesis for GM that air quenching of\u00a0cylinder heads would be a benefit over water\u00a0quenching because of an overall reduction\u00a0in residual stresses. The results showed significant\u00a0stresses remained with air quenching\u00a0deep inside the cylinder heads, at a depth of\u00a0about one centimetre.<\/p>\n

On the second research area of directly\u00a0observing phase precipitation during solidification,\u00a0GM uses modelling software to try to\u00a0predict the properties of the components or\u00a0alloys after they solidify, but sometimes the\u00a0models fail to predict the actual results. Neutrons\u00a0can uniquely identify phases that precipitate\u00a0during solidification. In other words,\u00a0they allow GM to \u201cwatch\u201d the solidification\u00a0process experimentally to better understand\u00a0what is causing the discrepancies.<\/p>\n

The third research area is concerned with\u00a0\u201ccreep testing,\u201d which in essence means determining\u00a0how the shape of the part may change\u00a0over time and eventually fail or cause problems.\u00a0The neutron beam experiments allow\u00a0GM to look at how the arrangement of the\u00a0atoms is changing in the material to better\u00a0understand how these changes take place.<\/p>\n

Neutrons help Ford<\/strong><\/p>\n

CNL has an ongoing research project\u00a0with Ford to examine new ways of joining\u00a0dissimilar materials together to be used in\u00a0light-weight vehicles. For example, self-piercing\u00a0riveting (SPR) is a leading alternative to\u00a0traditional welding methods, and has been\u00a0widely used by Audi, Mercedes, BMW, and\u00a0Jaguar, as well as Ford on their aluminum cars\u00a0and sports utility vehicles. SPR joints have\u00a0excellent mechanical properties and high\u00a0fatigue resistance. But the 3D residual stress\u00a0field in a mixed metal SPR joint had not\u00a0been experimentally studied before, making\u00a0prediction of fatigue life of such SPR joints\u00a0difficult. Ford turned to CNL\u2019s neutron beam\u00a0capability because other ways of determining\u00a0stresses were too difficult, considering\u00a0the complex geometry and number of different\u00a0materials involved. It plans to use the\u00a0results from the neutron analysis to validate\u00a0its existing residual stress prediction method,\u00a0and document these findings to inform\u00a0broader manufacturing processes.<\/p>\n

\u201cWe know there are tremendous opportunities\u00a0in the automotive and related\u00a0advanced manufacturing sectors,\u201d concludes\u00a0Gillespie. \u201cThese industries are capital\u00a0intensive and commercially focused with\u00a0resources dedicated to R&D [research and\u00a0development] advancement. We are confident\u00a0that in the near future CNL will be\u00a0regarded as a valued supply chain partner\u00a0and an active participant in their respective\u00a0product development and quality assurance\u00a0programs.\u201d<\/p>\n

International discussions are also driving\u00a0work in this area. The recently announced\u00a0United States-Canada Clean Energy Dialogue,\u00a0initiated by Prime Minister Stephen\u00a0Harper and President Barack Obama, recognizes\u00a0lighter-weight, sustainable materials\u00a0as a key research area in the development of\u00a0next-generation vehicles.<\/p>\n

In addition to neutron beams, CNL is\u00a0offering potential customers a wide range of\u00a0expertise and facilities that it has been using\u00a0to solve unique problems for clients outside\u00a0the nuclear industry, including surface science\u00a0tools and burst testing services, to name\u00a0a couple examples.<\/p>\n

About CNL<\/strong><\/p>\n

Canadian Nuclear Laboratories is a world\u00a0leader in nuclear science and technology\u00a0offering unique capabilities and solutions\u00a0across a wide range of industries. Actively\u00a0involved with industry-driven research and\u00a0development in nuclear, automotive, aerospace,\u00a0defence, security and life sciences, we\u00a0provide solutions to keep these sectors competitive\u00a0internationally.<\/p>\n

With ongoing investments in new\u00a0facilities and a focused mandate, Canadian\u00a0Nuclear Laboratories is well positioned\u00a0for the future. A new performance standard\u00a0reinforced with a strong safety culture\u00a0underscores every activity.<\/p>\n

For more information on the complete\u00a0range of services at Canadian Nuclear Laboratories,\u00a0please visit www.cnl.ca<\/a> or contact\u00a0communications@cnl.ca.<\/p>\n","protected":false},"excerpt":{"rendered":"

This article was originally printed in the Winter\/Spring 2015 edition of Lead, Reach and Connect, which is published twice per year for the Automotive Parts Manufacturers\u2019 Association (APMA). It has been reprinted with permission from the APMA and Matrix Group Publishing Inc. and cannot be reproduced without prior written consent. To view the full edition […]<\/p>\n","protected":false},"author":1,"featured_media":0,"comment_status":"closed","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[537],"tags":[],"topic":[],"class_list":["post-27930","post","type-post","status-publish","format-standard","hentry","category-talknuclear"],"acf":[],"yoast_head":"\nApplying Nuclear Expertise to Solve the Auto Industry's Challenges - Association nucl\u00e9aire canadienne<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/cna.ca\/fr\/2015\/02\/20\/applying-nuclear-expertise-to-solve-the-auto-industrys-challenges\/\" \/>\n<meta property=\"og:locale\" content=\"fr_FR\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Applying Nuclear Expertise to Solve the Auto Industry's Challenges - Association nucl\u00e9aire canadienne\" \/>\n<meta property=\"og:description\" content=\"This article was originally printed in the Winter\/Spring 2015 edition of Lead, Reach and Connect, which is published twice per year for the Automotive Parts Manufacturers\u2019 Association (APMA). 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