Integration of Microporosity Prediction in Durable and Robust Component Designs of Highly Loaded Aluminum Castings

M.Sc. M. Weidt, MAGMA Gießereitechnologie GmbH, Aachen

Prof. Dr.-Ing. A. Bührig-Polaczek, Gießerei-Institut, RWTH Aachen University

Abstract

Highly loaded cast aluminum components continue to be subjected to strong pressure to increase power density, particularly through increased specific loads or by weight reduction. In order to achieve these goals, it is necessary to fully exploit the material-specific performance potential. At the same time, robust manufacturing processes require precise knowledge of the main influencing variables, which in complex interaction link process parameters, component design and component performance. A closed simulation chain and the systematic use of virtual test plans (DoE) promise the targeted development of components and the design of their production in the casting process. This paper presents in detail one of the main influencing variables in the simulation chain, the relationship between the existing local porosity and the resulting defect size. In an integrated approach, the obtained information will be used to predict the local fatigue strength, together with the residual stress state, for an aluminum cylinder head. By validation component tests it can be shown that only this integrated approach allows a satisfactory failure prediction under cyclic loading.

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