Integration of Basic Materials Research Into the Design of Cast Components by a Multi-Scale Methodology

[+] Author and Article Information
Ken Gall

Department of Mechanical Engineering, University of Colorado, Boulder, CO 80309

Mark F. Horstemeyer

Materials & Engineering Sciences Center, Sandia National Laboratories, Livermore, CA 94550

J. Eng. Mater. Technol 122(3), 355-362 (Mar 16, 2000) (8 pages) doi:10.1115/1.482809 History: Received January 15, 2000; Revised March 16, 2000
Copyright © 2000 by ASME
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Overall philosophy of the multi-scale analysis for incorporating basic materials research into the component design process. Here we consider only monotonic loading, although cyclic loading has also been analyzed.
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Representative micrograph of A356 aluminum. The light matrix is Al-1 percent Si, and the dark specks are silicon particles.
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MEAM atomistic simulation demonstrating the strength of an Al-Si interface compared to pure Si or pure Al. All materials are defect free in the present simulation. Above the plot is a representative image of the bi-crystal simulation.
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(a) Number of damaged particles versus temperature and (b) corresponding load-displacement curves from notch tensile data (Gokhale et al. 12)
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Micromechanical finite element simulation of effective stress contours near damaged Si particles embedded in a Al-1 percent Si matrix. The black lines indicated bonding of the Al-Si interface, while the white spaces are cracks or debonds.
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(Top) Schematic mapping used to import realistic microstructural features onto a finite element grid. (Below) contour plot of volume fraction of damage (sdv 10) just before failure of the material at 12 percent strain.
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Stress-strain curves comparing the internal state variable constitutive model to experiments at different strain rates and temperatures for A356 Al (Horstemeyer et al. 7)
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Example of failure prediction analysis in a cast A356 automotive control arm. Sdv 13 is the void nucleation rate and sdv 14 is the damage volume fraction.



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