Influence of pores on crack initiation in monotonic tensile and cyclic loadings in lost foam casting A319 alloy by using 3D in-situ analysis

Abstract

Lost Foam Casting (LFC) process is replacing the conventional gravity Die Casting (DC) process in automotive industry for the purpose of geometry optimization, cost reduction and consumption control. However, due to lower cooling rate, LFC produces in a coarser microstructure that reduces fatigue life. In order to study the influence of the casting microstructure of LFC Al-Si alloy on damage micromechanisms under monotonic tensile loading and Low Cycle Fatigue (LCF) at room temperature, an experimental protocol based on the three dimensional (3D) in-situ analysis has been set up and validated. This paper focuses on the influence of pores on crack initiation in monotonic and cyclic tensile loadings. X-ray Computed Tomography (CT) allowed the microstructure of material being characterized in 3D and damage evolution being followed in-situ also in 3D. Experimental and numerical mechanical fields were obtained by using Digital Volume Correlation (DVC) technique and Finite Element Method (FEM) simulation respectively. Pores were shown to have an important influence on strain localization as large pores generate enough strain localization zones for crack initiation both in monotonic tensile and cyclic loadings.