Thesis Worker - Recycled Material on Mechanical Properties: Analysis of HPDC Aluminium for Structura

Thesis Worker at Volvo Cars

Welcome to explore the world of Volvo Cars by writing your thesis with us! As a thesis worker in our organization, you are supported by a supervisor who follows you during your project. All thesis projects are arranged in business-critical areas, allowing you to contribute to our company purpose – providing freedom to move in a safe, sustainable, and personal way – from day one!

Background

Cast aluminium is increasingly being used in structural applications within the automotive industry, exemplified by Volvo’s Megacastings. The final mechanical properties of these components depend on raw material sources, production, and the casting process. Defects such as oxides and pores can arise during these stages, affecting the material properties, particularly fracture behavior. Volvo Cars aims to increase the usage of recycled material as part of its sustainability goals. Utilizing recycled aluminium can cut CO2 emissions and energy usage by up to 95% compared to primary sources. However, recycled aluminium may contain higher levels of inclusions and trace elements that could compromise its mechanical performance.

Scope

This project aims to examine a Volvo-designed prototype High-Pressure Die Casting intended for structural applications, focusing on various chemical compositions linked to the proportion of recycled content. The evaluation will involve multiple methods of mechanical testing and microstructure analysis, including the study of alloy impurities and intermetallic phases. Test results and observed cast defects will be compared against cast process simulations to determine the impact of defects related to the casting process. Additionally, the project includes opportunities to investigate metallic phase formation through computer simulations of phase diagrams.

Tasks will include:

- Conducting mechanical tests such as three-point bending, compression, and tensile tests on both components and coupons.
- Characterizing the micro-scale microstructure to establish a connection between microstructure and mechanical properties.
- Performing correlation studies between recycled content, chemistry, microstructure, and mechanical properties in high-pressure die cast aluminium.
- Comparing outcomes of cast defects against cast simulations.
 

Do you fit the profile?

We are looking for students with a background in material sciences and an interest in aluminium alloys. Preferred skills include imaging, CALPHAD Thermo-calc software, and mechanical testing.

The project will mainly be performed on-site at Volvo Cars in Gothenburg, Torslanda.

Duration

This thesis project is scheduled for the spring term of 2025.

How to learn more and apply

Selection will be ongoing during the application period, so do not hesitate to send in your application. Attach your CV and a personal letter stating your interests within the given area and your thoughts and credentials.

Apply as soon as possible but no later than 2024-11-25.

Please note that applications via email will not be accepted.

If you have any additional questions regarding the thesis work, you are welcome to contact: Johan Nordström, johan.nordstrom@volvocars.com (Manager) or Anton Hultmark (anton.hvitt.hultmark@volvocars.com)

Who are we?

Everything we do starts with people. Our purpose is to provide freedom to move, in a personal, sustainable and safe way. We are committed to simplifying our customers’ lives by offering better technology solutions that improve their impact on the world and bringing the most advanced mobility innovations to protect them, their loved ones and the people around them.

Volvo Cars’ continued success is the result of a collaborative, diverse, and inclusive working environment. The people of Volvo Cars are committed to making a difference in our world. Today, we are one of the most well-known and respected car brands, with over 40,000 employees across the globe. We believe in bringing out the best in each other and harnessing the true power of people. At Volvo Cars your career is designed around your talents and aspirations so you can reach your full potential. Join us on a journey of a lifetime as we create safety, autonomous driving and electrification technologies of tomorrow