Mechanical Engineering - Theses
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ItemMass reduction of fatigue-limited, safety-critical (FLSC), ferrous metal automotive components by forged light alloy substitution( 2006)The substitution of ferrous metal with forged light alloys in Fatigue-Limited, Safety- Critical (FLSC) applications provides an opportunity to achieve mass reduction. However, the use of forged light alloys in FLSC applications is limited by: * the complexity and uncertainties inherent in fatigue-limited design * material selection procedures that do not actively engage with the unique requirements of light alloys * a limited understanding of the technical design, manufacture and test requirements for light alloy production * limited available data on the optimisation of light alloy processing for fatiguelimited applications This thesis offers original contributions to the design and manufacture requirements associated with mass reduction of FLSC ferrous metal automotive components by forged light alloy substitution. Original contributions include: * enhanced concept generation and project management tools (Chapter 2) * design tools to assist the resolution of complexity and uncertainty in fatigue-limited design (Chapter 3) * novel material selection methods for fatigue-limited design (Chapter 4) * novel experimental outcomes on the influence of billet processing on the fatigue strength of an important light alloy (Chapter 6).