Development of new casting aluminium alloys: composition,

microstructure and mechanical properties

Priyansh Khandelwal

Research Statement:
Materials science and engineering play a pivotal role in advancing technologies across
industries, and the quest for lightweight, strong, and ductile materials remains a paramount
goal. The project "Development of New Casting Aluminium Alloys: Composition,
Microstructure, and Mechanical Properties" represents a compelling opportunity to
contribute to this endeavor. This research aims to unlock the potential of aluminium alloys
by investigating the intricate relationships between composition, microstructure, and
mechanical properties, with a particular focus on the role of rare-earth and transition
metallic elements.

Project Overview:
The overarching objective of this PhD project is to develop a comprehensive understanding
of the influence of rare-earth and transition metallic elements on the microstructure and
mechanical properties of casting aluminium alloys. While the advantages of these elements
in strengthening aluminium alloys have long been recognized, their widespread industrial
use has historically been hindered by cost and processing challenges. This project,
generously funded by an industrial partner, addresses this issue by combining
thermodynamic calculations and physical experiments to investigate the full spectrum of
possibilities for enhancing aluminium alloys.

Research Methodology:
The research methodology for this project is multifaceted, integrating theoretical and
experimental approaches:

1. Computational Modeling (Thermodynamics Calculations): Advanced software tools,

such as Thermo-Calc, will be employed to perform thermodynamic calculations.
These calculations will aid in predicting phase equilibria, solubility limits, and the
stability of different phases in complex aluminium alloy systems. The aim is to
determine the optimal compositions for achieving desired microstructures and
properties.
2. Experimental Investigation: Complementing the computational work, physical
experiments will be conducted in the laboratory. These experiments will involve the
preparation and casting of aluminium alloys with controlled compositions.
 Techniques such as microscopy, mechanical testing, and microstructural analysis will
be employed to characterize the resulting materials.
3. Microstructure-Property Correlations: By comparing computational predictions with
experimental results, we will establish correlations between alloy compositions,
microstructural features (including grain size, phase distribution, and precipitates),
and mechanical properties (e.g., tensile strength, hardness, and ductility). This
analysis will provide critical insights into the strengthening mechanisms of rare-earth
and transition metallic elements in aluminium alloys.
4. Optimization: Through a systematic approach, this project will strive to optimize
aluminium alloy compositions to achieve enhanced mechanical properties. This will
involve fine-tuning the alloy's microstructure by leveraging the insights gained from
both computational modeling and experiments.

Expected Outcomes:
This research holds the promise of several significant outcomes:

 Novel Aluminium Alloys: The project aims to develop new casting aluminium alloys
with improved strength, ductility, and other desirable mechanical properties, making
them highly attractive for applications in industries where lightweight, high-
performance materials are essential.
 Fundamental Understanding: By unraveling the intricate interplay between alloy
composition, microstructure, and mechanical properties, this project will contribute
to our fundamental understanding of materials science, benefiting future research
and innovation.
 Cost-Effective Solutions: The research intends to address the historical cost and
processing challenges associated with rare-earth and transition metallic elements,
potentially opening up cost-effective avenues for industrial applications.
 Collaboration and Knowledge Exchange: Collaboration with industrial partners and
academic peers will foster knowledge exchange and promote the practical
application of research findings.

Conclusion:
In summary, the project "Development of New Casting Aluminium Alloys: Composition,
Microstructure, and Mechanical Properties" embodies a compelling fusion of computational
modeling and experimental research in the field of materials science and engineering. The
research seeks to unlock the full potential of aluminium alloys, with the ultimate goal of
developing advanced materials that can revolutionize industries by offering a combination
of lightweight design, superior strength, and enhanced performance. This project represents
not only a significant contribution to materials science but also a promising opportunity to
drive innovation and address real-world industrial challenges.