Influence of the Lost Foam Casting microstructure on low cycle fatigue damage of A319 aluminum alloy

  • Nora Dahdah
  • , Nathalie Limodin
  • , Ahmed El Bartali
  • , Jean François Witz
  • , Rian Seghir
  • , Long Wang
  • , Eric Charkaluk
  • , Jean Yves Buffiere

Research output: Chapter in Book/Report/Conference proceedingConference contributionpeer-review

Abstract

In cast aluminum alloys used in the automotive industry the microstructure inherited from the foundry process has a strong influence upon the fatigue behavior. In the cylinder heads produced by the Lost Foam Casting process, the microstructure consists of hard intermetallic phases and large gas and microshrinkage pores. In order to study the influence of this complex 3D microstructure on fatigue crack initiation and propagation, an experimental protocol using laboratory and synchrotron tomography, Finite Element simulation and 3D Digital Volume Correlation has been used. Full field measurements at the microstructure scale were performed during a low cycle fatigue test at room temperature performed in situ under synchrotron X-ray tomography (TOMCAT beamline, SLS). Synchrotron tomography allowed characterizing the eutectic Al-Al2Cu, iron based intermetallics phases and above all eutectic Si, which could not be distinguished with laboratory tomography; these constituents were proved a suitable natural speckle for Digital Volume Correlation. The 3D cracks were observed to initiate at large pores and then to propagate along the hard inclusions towards the free surface. The DVC of in-situ fatigue tests allows observing the relations between cracks and displacements discontinuities and strain localizations in measured field. The experimental protocol proposed will be further improved for a validation at a temperature characteristic of in-service conditions of cylinder heads (250°C).

Original languageEnglish
Title of host publication3DMS 2014 - Proceedings of the 2nd International Congress on 3D Materials Science
EditorsDominique Bernard, Jean-Yves Buffiere, Tresa Pollock, Tresa Pollock, Henning Friis Poulsen, Anthony Rollett, Anthony Rollett, Anthony Rollett, Anthony Rollett, Michael Uchic
PublisherJohn Wiley and Sons Inc.
Pages97-102
Number of pages6
ISBN (Electronic)9781118945452
DOIs
Publication statusPublished - 1 Jan 2014
Event2nd International Congress on 3D Materials Science, 3DMS 2014 - Annecy, France
Duration: 29 Jun 20142 Jul 2014

Publication series

Name3DMS 2014 - Proceedings of the 2nd International Congress on 3D Materials Science

Conference

Conference2nd International Congress on 3D Materials Science, 3DMS 2014
Country/TerritoryFrance
CityAnnecy
Period29/06/142/07/14

Keywords

  • Aluminum-silicon alloys
  • Digital Volume Correlation
  • Synchrotron X-ray tomography

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