This content is not included in
your SAE MOBILUS subscription, or you are not logged in.
Prediction of Secondary Dendrite Arm Spacing in Directional Solidification of Aluminum Alloy by Casting Simulation and Micro-Structural Inspection
Technical Paper
2019-26-0166
ISSN: 0148-7191, e-ISSN: 2688-3627
This content contains downloadable datasets
Annotation ability available
Sector:
Language:
English
Abstract
In automotive industry, many of the powertrain components (for e.g. engine head and cylinder block) are generally manufactured by a casting procedure. Secondary Dendrite Arm Spacing (SDAS) is one of the most important microstructural features in dendritic solidification of alloys (for e.g. Al-Si alloys) during the casting process. SDAS has a significant influence on the mechanical behavior of the cast aluminum components. A lower value of SDAS is desired in order to achieve better fatigue strength of the cast components which can be controlled by governing several casting parameters. For directional solidification, SDAS is dependent on various casting parameters i.e. chemical composition of the alloy, cooling rate and liquid melt treatment. During industrial casting of an alloy with predefined chemical composition, cooling rate during the mushy zone becomes the dominant parameter for controlling SDAS. The objective of this study was to predict the SDAS of die cast Al-Si alloy samples subjected to different cooling rates by varying the mold temperature. The SDAS was predicted by a casting simulation and utilizing the empirical relationship between solidification time and SDAS. The predicted SDAS values from simulation were compared with the experimental results of SDAS obtained from the microstructural inspection of the cast samples. It was observed that the predicted SDAS were in good agreement with the inspected values. This study also showed an increasing trend of SDAS values with the increase in solidification time. The approach to calculate SDAS, described in this paper could be used as a design tool to compare the fatigue properties of cast aluminum components subjected to different casting parameters without any destructive fatigue failure testing.
Recommended Content
| Journal Article | Development of High Strength Mg Alloys |
| Technical Paper | Aluminum Alloys for Automotive Knuckle Castings |
Authors
- Nilankan Karmakar - General Motors Technical Center India
- Pankaj Jha - General Motors Global Propulsion System
- Sudipto Ray - General Motors Technical Center India
- Neeraj Carpenter - General Motors Technical Center India
- Akshay A. - General Motors Technical Center India
- Virupakshappa Lakkonavar - General Motors Technical Center India
- Michael Nienhuis - General Motors Global Propulsion System
Citation
Karmakar, N., Jha, P., Ray, S., Carpenter, N. et al., "Prediction of Secondary Dendrite Arm Spacing in Directional Solidification of Aluminum Alloy by Casting Simulation and Micro-Structural Inspection," SAE Technical Paper 2019-26-0166, 2019, https://doi.org/10.4271/2019-26-0166.Data Sets - Support Documents
| Title | Description | Download |
|---|---|---|
| Unnamed Dataset 1 | ||
| Unnamed Dataset 2 |
Also In
References
- Opportunities for Aluminium Components in Automotive Applications Charles Hatchett Seminar 2016
- Pavlovi Krsti , J. , Bähr , R. , Krsti , G. , and Puti , S. 2009
- Horwath , J.A. and Mondolfo , L.F. Dendritic Growth Acta Metall. 10 1037 1042 1962
- Spittle , J.A. and Lloyd , D.M. Solidification and Casting of Metals The Metals Society 1979 15 20
- Tunca , N. and Smith , R.W. Variation of Dendrite Arm Spacing in Al-Rich Zn-Al Off-Eutectic Alloys Journal of Materials Science 23 111 120 1988
- Rohatgi , P.K. , Madhava , M.R. , and Surappa , M.K. Potential New Solidification Experiments in Space Environment Bulletin of Materials Science 4 283 288 1982
- Djurdjevic , M. and Grzincic , M. The Effect of Major Alloying Elements on the Size of Secondary Dendrite Arm Spacing in the As-Cast Al-Si-Cu Alloys Archives of Foundry Engineering 12 19 24 2012
- Li , Z. , Samuel , A.M. , Samuel , F.H. , Ravindran , C. et al. Mater. Sci. Eng., A 367 96 110 2004
- Kurz , W. and Fisher , D.J. Fundamentals of Solidification Switzerland-Germany-UK-USA Trans. Tech. Publications 1984
- Gruzleski , J.E. and Closset , B.M. The Treatment of Liquid Aluminium-Silicon Alloys Third Des Plaines, IL American Foundryman’s Society, Inc. 1990
- Vandersluis , E. , Lombardi , A. , Ravindran , C. , Bois-Brochu , A. et al. Factors Influencing Thermal Conductivity and Mechanical Properties in 319 Al Alloy Cylinder Heads Mater. Sci. Eng. A 648 401 411 2015
- Kabir , M.S. et al. Effect of Foundry Variables on the Casting Quality of As-Cast LM25 Aluminium Alloy International Journal of Engineering and Advanced Technology 3 6 115 120 2014
- Flemings , M.C. Solidification Processing USA McGraw-Hill, Inc. 1974
- Ferreira , A.F. , da Silva , A.J. , and de Castro , J.A. Simulation of the Solidification of Pure Nickel via the Phase-Field Method Materials Research 9 4 349 356 2006
- Foundry Lexicon Website https://www.giessereilexikon.com/en/foundrylexicon/Encyclopedia/show/dendrite-arm-spacing-3345/
- Grugel , R.N. Secondary and Tertiary Dendrite Arm Spacing Relationships in Directionally Solidified Al-Si Alloys J. Mater. Sci. 28 677 683 1993
- Kattamis , T.Z. and Flemings , M.C. Transactions of the Metallurgical Society of ACME 233 992 1965
- Fuerer , U. Proceeding of Quality Control of Engineering Alloys and the Role of Metals Science Nieswaag , N. and Schwut , J.-W. Delft, the Netherland 1977 131