Experimental and numerical analysis of gas entrapment defects in plate ADC12 die castings

Zhao, Haidong; Wang, F.; Li, Y.Y.; Xia, Wei

doi:10.1016/j.jmatprotec.2008.10.028

Cited by 69 publications

(22 citation statements)

References 6 publications

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“…Due to the high injection velocity of molten metal in HPDC processes, turbulent filling flow often causes entrapment of the cavity gas and results in porosities in casting. 7) As a result, all the fatigue specimens have pores with different contents. The pores have different contrast than aluminum matrix in series images obtained by transmission Xray, and hence their 3D morphology in spatial are clearly visible after reconstruction.…”

Section: Methodsmentioning

confidence: 99%

“…Weiler 5) and Hu 6) studied relationship between internal porosity and fracture strength of die-cast magnesium alloys. In author's former research, 7) the influence of porosity size and fractions on the ADC12 die castings was investigated and the critical size and fraction were proposed for the qualified castings. Wang 8) used a two-parameter Weibull method to analyze fatigue life of A356 alloys with or without defects.…”

Section: Introductionmentioning

confidence: 99%

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Effect of Micro-porosities on Fatigue Behavior in Aluminum Die Castings by 3D X-ray Tomography Inspection

Zhao

Chun

2014

ISIJ Int.

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In this investigation, porosities in fatigue specimens obtained from practical ADC12 high pressure die castings were detected and reconstructed with high resolution X-ray computed tomography technology. Three dimensional (3D) characterizations of the porosities were analyzed. The high cycle fatigue tests were carried out at five stress amplitudes on seven groups of the specimens with different porosity contents. The Weibull analysis suggested less scatter of the fatigue life at larger stress condition. With the SEM observation on the fatigue fractured surfaces, the porosities initializing the fatigue cracks were identified. A pore-fatigue life prediction equation was deduced with the pore characteristics from the fracture surface and 3D X-ray tomography inspection. With 3D reconstruction of tomography data and FEA method, the simulation of the stress distribution around the actual 3D pores were carried out and analyzed further.KEY WORDS: high pressure die casting; porosity; fatigue; three dimensional tomography; finite element analysis.

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Section: Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Effect of Micro-porosities on Fatigue Behavior in Aluminum Die Castings by 3D X-ray Tomography Inspection

Zhao

Chun

2014

ISIJ Int.

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“…There was a strong correlation between the porosity and mechanical properties of the cast Al alloys, in which the parameter of global volumetric porosity was used. [7] In the study by Zhao et al, [8] the tensile properties of Al-Si-Cu cast plate samples were found to be directly affected by porosity. The effects of porosity on mechanical properties have been investigated by several researchers (e.g., [9] ).…”

Section: Introductionmentioning

confidence: 97%

The Effects of Defects on Tensile Properties of Cast ADC12 Aluminum Alloy

Okayasu

Sakai

2015

Metall Mater Trans A

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To better understand the effects of cast defects on mechanical properties, cast aluminum alloys with various porosities were used. Porosity in the cast samples was created during the casting process, and to clearly identify the porosity effects on the mechanical properties, artificial defects (porosity-like tiny holes) were created mechanically. The tensile properties for the cast aluminum alloys appear to be attributed to the area fraction of the porosity on the fracture surface (namely, the defect rate, DR), although there were different trends because of the different stress concentrations: the ultimate tensile strength and 0.2 pct proof strength were linearly related to DR, while a non-linear correlation was detected for fracture strain. Even in Al alloys with small amounts of defects, significant reductions in the fracture strain were observed. These results were verified using tensile tests on specimens containing artificial defects. The effects of artificial defects on the tensile properties were further investigated using numerous tiny holes, created in several formations. The artificial defects (several small holes), lined up at perpendicular (90 deg) and 45 deg directions against the loading direction, made significant reductions in the tensile properties, even though only weak defect effects were observed for the 90 deg loading direction. No severe defect effects were obvious for the specimen with a tiny defect of /0.1 mm, because of the lower stress concentration, compared to the microstructural effects in the cast Al alloys: the grain boundaries and the second phases. Such phenomena were clarified using tensile tests on cast samples with differently sized microstructures. There were no clear defect effects on the yield strength as the defect amount was less than 10 pct, and microstructural effects were not detected either in this case. Failure characteristics during tensile loading were revealed directly by in-situ strain observations using high-speed cameras.

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“…As a kind of aluminum-silicon alloys, the ADC12 aluminum alloy is extensively used in the automotive industry to reduce vehicle weight as well as to improve fuel economy [1][2][3][4]. The commercial importance of these alloys is based on their high fluidity and low shrinkage properties in casting, brazing and welding applications.…”

Section: Introductionmentioning

confidence: 99%

Effects of rare earth Er additions on microstructure development and mechanical properties of die-cast ADC12 aluminum alloy

Fu-gang

et al. 2012

Journal of Alloys and Compounds

137

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Experimental and numerical analysis of gas entrapment defects in plate ADC12 die castings

Cited by 69 publications

References 6 publications

Effect of Micro-porosities on Fatigue Behavior in Aluminum Die Castings by 3D X-ray Tomography Inspection

Effect of Micro-porosities on Fatigue Behavior in Aluminum Die Castings by 3D X-ray Tomography Inspection

The Effects of Defects on Tensile Properties of Cast ADC12 Aluminum Alloy

Effects of rare earth Er additions on microstructure development and mechanical properties of die-cast ADC12 aluminum alloy

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