Abstract
Aluminium casting exceptionally an excellent candidate in replacing wrought structural components in various industries. The microstructure and defects introduced during the casting process must be then quantified for the strength requirements, particularly on their effect on fatigue performance either by experimental or modelling or by both. The quality of cast structure is also equally becoming pervasive, but it is yet elusive. The metal defects in the casting structure is mainly depends on solidification time, alloying element and standardized mould. The understanding of role of porosity on fatigue properties of cast structures is still outstanding. The analytical and empirical framework of stochastic assessment of fatigue life of aluminium cast structures is described in this paper not only to understand the stochastic nature of both fatigue and porosity but also to define the rejection limit on the cast aluminium structures based on established analytical fatigue limit for random porosity which is expected to be within the specified range. This paper describes the stochastic fatigue model for the purpose of defining the acceptable limit of the casting structures used in aero engine applications. Experimentally produced fatigue life is then compared with the data from stochastically generated fatigue life with good matching trend. The proposed stochastic fatigue model is then used to define the acceptance criteria on quality of casting.
Published Version
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