Influences of Porosity Shapes and Sizes on Stress and Strain Fields in the Casted Aluminum Using Finite Element Modelling

Casted Aluminum alloys are prone to manufacturing defects such as porosity, voids, and inclusions. Modern casting systems, with their advanced technologies, have made strides in foreseeing and mitigating these flaws. Yet, apart from inclusions and porosity remain stubbornly persistent, never fully eradicated. The challenge of predicting the exact sizes and shapes of these flaws adds another layer of complexity. Consequently, the precise predictions of stress-strain fields, while accounting for casting defects are critical to ensure the durability and integrity of casted components. A computational finite-element based simulation performed to resemble the experimental tensile test. A quarter symmetric numerical specimens are investigated with distinct sizes and shapes of pores/voids. The tensile strength along with the elasto-plastic stress-strain state in the vicinity of randomly distributed voids/pores are determined and compared with defects-free model. The local stress and strain concentrations at different locations of pores are determined and presented based on void/pore’s shape and size. The cumulative influence of porosity shapes and sizes on the durability of aluminum casted components are thoroughly examined, and the significance of this analysis is demonstrated.