Very High Cycle Fatigue Properties and Damage Evolution in Al-Si Cast Alloys

Abstract

Abstract The steady progress in electro mobility increases the demand for lightweight space frame and engine solutions. Advanced aluminum-silicon cast alloys with additions of magnesium, copper, or both for precipitation hardening are promising candidates for lightweight structures because of their high strength-to-weight ratio. For a reliable design, the fatigue performance in the very high cycle fatigue (VHCF) regime must be understood. Therefore, this study deals with the influence of frequency on VHCF properties as well as fatigue damage evolution in AlSi7Mg and AlSi10Mg sand-cast alloys. The VHCF tests were performed using a resonant (70 Hz), a high-frequency resonant (1 kHz), and an ultrasonic (20 kHz) fatigue testing system. Thereby, a significant frequency effect could be determined that resulted in an increased fatigue lifetime by 1 decade at 1 kHz and by 2 decades at 20 kHz, whereas no significant change in fatigue limit could be determined. Moreover, the fatigue crack initiation mechanisms change from surface crack initiation at 70 Hz and 1 kHz to volume crack initiation at 20 kHz. Using the defect-based Murakami approach, including a lightweight extension of Noguchi, a defect-induced (size, location) frequency effect could be excluded. Based on damage monitoring, the effect could be related to the crack propagation phase, which is accelerated at low frequencies (<100 Hz) because of a humidity reaction with the fatigue crack surface and the formation of atomic hydrogen resulting in a saturated hydrogen embrittlement per cycle. At high frequencies of 1 kHz and 20 kHz, no saturated hydrogen embrittlement per cycle can be reached.