Influence of surface and internal casting defects on the fatigue behaviour of A357-T6 cast aluminium alloy

Serrano-Muñoz, Itziar; Buffière, Jean‐Yves; Verdu, Catherine; Gaillard, Yves; Mu, Peng; Nadot, Y.

doi:10.1016/j.ijfatigue.2015.07.032

Cited by 97 publications

(62 citation statements)

References 31 publications

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“…The crack path resulting from surface propagation at Pore 1 is relatively rough and the growth direction is almost perpendicular to the loading axis (Z). On the contrary, the internal crack which nucleated from Pore 3 exhibits large facets and oblique growth (in this case at −60°): a crack morphology similar to what is obtained under vacuum conditions26. It must be noted that, occasionally, some perpendicular growth can be also observed around Pore 3 (Fig.…”

Section: Resultssupporting

confidence: 74%

“…The crack growth rate has also been evaluated using linear measurements of the crack length a performed every 20° around the two crack fronts: the average of the linear measurements a (over 10 counts for Crack 1 and 16 for Crack 3) are in good agreement with the results shown on Fig. 3 and show the same trend, i.e., a slower crack growth rate for the internal crack37.…”

Section: Resultssupporting

confidence: 62%

“…When no such defects are present, crack nucleation is induced by other microstructural parameters such as favourable grain orientations or Si particles2425. Internal failure in cast Al alloys is however rarely observed during high cycle fatigue (10 5 < N cycles failure < 10 7 ) and, when it occurs, it does not entails a reduction of the expected fatigue life2627. As for the environmental conditions of internal cracking, they are generally considered to be close to those of vacuum as their fracture surface features look similar262829.…”

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confidence: 99%

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Location, location & size: defects close to surfaces dominate fatigue crack initiation

Serrano-Muñoz

Buffière

Mokso

et al. 2017

Sci Rep

118

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Metallic cast components inevitably contain defects such as shrinkage cavities which are inherent to the solidification process. Those defects are known to significantly alter the fatigue life of components. Yet very little is known, quantitatively, on the dangerosity of internal casting defects compared to surface ones. In this study, fatigue specimens containing controlled internal defects (shrinkage pores) are used to foster internal cracking. In situ fatigue tests monitored by X ray synchrotron tomography revealed that the internal nucleation and propagation of cracks was systematically overran by surface cracking initiated at castings defects up to ten times smaller than the internal ones. These findings indicate that the presence of internal defects in cast components can be tolerated to a larger extent than is allowed by nowadays standards

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Section: Resultssupporting

confidence: 74%

Section: Resultssupporting

confidence: 62%

mentioning

confidence: 99%

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Location, location & size: defects close to surfaces dominate fatigue crack initiation

Serrano-Muñoz

Buffière

Mokso

et al. 2017

Sci Rep

118

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“…report the manufacturing process, the static and dynamic mechanical properties and the size of the dendrites, which are the microstructural features (whose direction and size depend on the cooling process) that most affect the fatigue resistance of the material [54,61]. The tables contain some other significant parameters, including i) the mean grain size [33,34] (which is reported by some authors as CPUA), ii) the effect of hot isostatic pressing [35] and iii) the iron content [51].…”

Section: Scope On Fatigue Strength In Presence Of Defectsmentioning

confidence: 99%

“…For AlSi10Mg, the most common process is a peak hardening to the T6 condition, which ensures an improvement in the fatigue resistance of cast parts (comparing the data in [49,50] to [33,48] for R = 0.1 and to [52] for R = −1 in Tab. 2).…”

Section: Thermal Treatmentmentioning

confidence: 99%

A comparison of fatigue strength sensitivity to defects for materials manufactured by AM or traditional processes

Beretta

Romano

2017

International Journal of Fatigue

476

229

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Microstructure and fracture behavior of Al‐Si‐Mg alloy prepared with recycled alloy

Song

Liu

Nie

et al. 2019

Materialwissenschaft Werkst

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In this paper, microstructure and fracture behavior of Al‐Si‐Mg alloy prepared with recycled alloy were studied. The results show that some casting defects such as oxidation slags, pores and iron‐rich intermetallic phases exist in the alloy prepared with recycled alloy. Stress concentration forms in the tips of the pores and iron‐rich intermetallic phases in the process of stretching. Cracks are easy to initiate near slags due to the weakening of the adhesion between the oxidized slag and the aluminum matrix. In addition, silicon phases play a hindering role on the movement of dislocations in the process of crack propagation and merging of cracks which is strengthening the alloy prepared with recycled alloy to some extent. Crack propagation is mainly along the direction of casting defects, and the cracks connect with each other until failure of material. Moreover, the crack originate from silicon phase and extend along the eutectic structure of alloy no‐containing recycled alloy, and a large plastic deformation occurred in the α‐aluminum dendrites.

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Influence of surface and internal casting defects on the fatigue behaviour of A357-T6 cast aluminium alloy

Cited by 97 publications

References 31 publications

Location, location & size: defects close to surfaces dominate fatigue crack initiation

Location, location & size: defects close to surfaces dominate fatigue crack initiation

A comparison of fatigue strength sensitivity to defects for materials manufactured by AM or traditional processes

Microstructure and fracture behavior of Al‐Si‐Mg alloy prepared with recycled alloy

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