Goal of the LEA joint project is the development of virtual tools for a consistent exploitation of lightweight design capability of ADI components. These virtual tools will adjust the ADI material properties, propose an appropriate process structuring, and predict the operating behavior.
ADI material (Austempered Ductile Iron) offers great lightweight design capability. Because of knowledge-gaps and demanding production processes it is not able to make an entire use of it. Hence the component-bound material properties at operating, extra and misapplication load will be researched and methods for material behavior prediction provided. The researches and methods will close the gaps and increase acceptance of ADI materials.
Within the project, properties of ADI castings and of samples taken out of it will be investigated under cyclic and tensile load. The different microstructure states and casting defects will be considered. With these data methods of component optimization and improved durability calculation will be developed. In this context ADI heat treatment models are essential for describing the physical procedures. MAGMA will develop these models and implement them into MAGMAiron.
The methods of durability calculation and virtual process and component optimization will be integrated into the development process; design guidelines will be established. This is the basis for an entire use of ADI materials lightweight design capability and hence for series-production of ADI material for safety components in vehicle construction.