A physics-based defect tolerant design approach to predict the tensile performance of aluminium alloys with a defect

Abstract

Inherent manufacturing defects are observed in additively manufactured and casted metallic alloys. During loading, the stress concentration due to defect results in poor tensile ductility and fatigue performance. A physics-based defect tolerant design approach is used in the present work to calculate the uniaxial tensile performance of cast ADC12 Aluminum alloys. The proposed model elucidates the correlation between tensile ductility and the dimensions of material defects. It derives a material constant referred to as the critical defect size, which is determined through a combination of uniaxial tensile testing on specimens with defects and employing finite element simulations. The proposed approach calculates well the tensile properties such as complete tensile stress–strain curve, ultimate tensile strength, and uniaxial tensile elongation.