Tensile tests have been conducted on die-cast coupons of an Al-Si-Cu alloy, which found to contain no pores via X-ray inspection. Due the digital image correlation used during tensile testing, either single or multiple strain concentrations detected and subsequently characterized. In all cases, oxide films fracture surfaces at site concentrations. The analysis a crack away from surface has also shown it be bifilm. These results pour doubt effectiveness quality assurance practices employed in...

Abstract A new methodology leverages virtual casting process simulations to predict the statistical distribution of local mechanical properties, based on computed microstructures and defects. The extensive result sets generated from each simulation can be statistically evaluated in a manner similar numerous individual tensile tests. By incorporating variability into simulation, this innovative approach enables probabilistic modeling expected properties. Consequently, method supports...

This study focuses on the modelling and simulation of local mechanical properties compacted graphite iron cast at different section thicknesses three levels silicon, ranging from about 3.6% up to 4.6%. The relationship between tensile microstructure is investigated using microstructural analysis statistical evaluation. Models are generated response surface methodology, which reveal that silicon level nodularity mainly affect strength 0.2% offset yield strength, while Young′s modulus...

The competition between pores and hidden entrainment defects during tensile testing of specimens from Al-Si-Cu alloy high-pressure die castings has been characterized. In all tests, multiple strain concentrations have identified by using the digital image correlation technique final fracture preceded a damage, later as oxide bifilms. results confirmed previous findings that overall damage to metal its liquid state is much more extensive than what can be assessed via X-ray inspection, which...

The mechanical behaviour and performance of a ductile iron component is highly dependent on the local variations in solidification conditions during casting process. Here we show framework which combine previously developed closed chain simulations for cast components with micro-scale Finite Element Method (FEM) simulation microstructure. A process simulation, including modelling material characterization, provides basis macro-scale FEM analysis component. critical region identified to...

Abstract Pores have been the main focus of quality assurance in castings. Latest research has shown that aluminium castings pores can form only if there is existing entrainment damage, i.e., are merely visible parts and usually invisible damage much more extensive. However, its effect on deformation behaviour not previously established or observed in-situ. This work applies 2D Digital Image Correlation (DIC) to an in-situ full-field stress-strain analysis tensile samples with a...

Abstract A novel approach to incorporate local microstructure-based material performance into finite element method (FEM) simulations of cast components is presented. By adopting perspectives from natural designs as dinosaur skulls and trees, the discipline-wide enables accurate prediction damage in structures based on a heterogeneous distribution sub-scale features. It shown that tolerance dictates failure aluminum, are compared with experimental results tensile samples using digital image...

Abstract In this work, an integrated simulation approach previously developed for static FE analyses is extended to microstructure- and defect-based fatigue life assessments of castings. The approach, the closed chain simulations cast components , combines casting process with microstructure modelling local material characterisation generate heterogeneous data analysis assessment. method demonstrated on a High-Pressure Die Cast aluminium component. Areas high risk defects are identified...

Abstract An approach to evaluate and quantify process variability in the mechanical performance of castings is explored. The describes effect hidden damage given metal before solidification on material measured by elongation failure. demonstrated a casting produced high-pressure die (HPDC) with different filling conditions serial production. Statistical analyses have been conducted data obtained from several positions throughout determine whether position performing differently other...

The industrial demand for increased component performance with concurrent reductions in weight, development times and verifications using physical prototypes drives the need to use full potential of casting Finite Element Method (FEM) simulations correctly predict mechanical behavior cast components service. is determined by process, factors as geometry process parameters are known affect solidification microstructure formation throughout cause local variations well residual stresses. Though...

The coupling between simulations of solidification, microstructure and local mechanical behaviour simulation stress-strain is studied by applying a recently developed strategy to high pressure die cast aluminium component. In the strategy, named closed chain for components, throughout component determined locally casting process simulation. entire process, including mould filling simulated predict formation residual stresses component, material characterization models are applied relate...

A literature review on methods to consider the mechanical behaviour of cast aluminium alloys in finite element method (FEM) simulations components has been performed. The is related several microstructural parameters achieved during casting process. Three different these are introduced. One predicts component using process simulation software. other two implement numerical models for into FEM simulation. Applications shown, including combinations with statistical and geometry optimisation...