TMF–LCF life assessment of a Lost Foam Casting A319 aluminum alloy

Abstract

The LFC (Lost Foam Casting) process affects the microstructure, the mechanical properties, the damage mechanisms and the fatigue failure of the materials. The first purpose of this paper is to study the cyclic mechanical behaviors, damage and lifetime of the A319 aluminum alloy manufactured by the LFC process used in the automotive industry under TMF (Thermo-Mechanical Fatigue) and LCF (Low Cycle Fatigue) conditions. A second objective is to select an effective fatigue criterion which should be easy to apply for the design of structures submitted to complex multiaxial thermo-mechanical loadings. In this way, several energy-based criteria are used to predict fatigue failure. Good agreement between predicted fatigue lifetimes and experimental results was obtained for different TMF and LCF loading conditions.

Thermal fatigue analysis of automotive Diesel piston: Experimental procedure and numerical protocol

“…A fatigue lifetime criterion used here is based on dissipated energy as proposed by previous authors [18][19][20][22][23][24].…”

“…Under LCF conditions, this approach was proven to have a physically bases sound when the life is mainly controlled by micro-crack growth [21,[23][24][25][26][27][28][29]. This approach is robust even though some modifications are sometimes necessary to account for the mean stress effects or multi-axial loading [30][31][32][33] and when oxidation or creep interacts with fatigue [21,[34][35].…”

Damage Investigation in A319 Aluminium Alloy by X‐ray Tomography and Digital Volume Correlation during In Situ High‐Temperature Fatigue Tests

“…Above a critical size, pores play a decisive role on the fatigue properties by providing preferential crack initiation sites. However, an influence of oxides , iron‐based intermetallics and Si particles are also observed. As a matter of fact, cracks can initiate at any large pores or hard phases present in bulk.…”

Effects of Casting Parameters on Shape Replication and Surface Roughness of LM6 Aluminium Alloy Cast Using Lost Foam Process

“…The rates of the liquidation and evaporation strongly depend on the casting parameters [5]. If the polystyrene residues are not completely eliminated and remain inside the mould, not only inclusion and residual defects [6,7] can possibly occur, but it may retard the melt from flowing causing premature solidification before the mould is fully filled. Therefore, there should be a dynamic balance between the back pressure and the metallostatic head.…”