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We examine the dependence of fatigue properties on the different size scale microstructural inclusions of a cast A356 aluminum alloy in order to quantify the structure-property relations. Scanning electron microscopy (SEM) analysis was performed on fatigue specimens that included three different dendrite cell sizes (DCSs). Where past studies have focused upon DCSs or pore size effects on fatigue life, this study includes other metrics such as nearest neighbor distance (NND) of inclusions, inclusion distance to the free surface, and inclusion type (porosity or oxides). The present study is necessary to separate the effects of numerous microstructural inclusions that have a confounding effect on the fatigue life. The results clearly showed that the maximum pore size (MPS), NND of gas pores, and DCS all can influence the fatigue life. These conclusions are presumed to be typical of other cast alloys with similar second-phase constituents and inclusions. As such, the inclusion-property relations of this work were employed in a microstructure-based fatigue model operating on the crack incubation and MSC with good results.

Many material properties are statistical in nature. If one measures the same property of the same material repeatedly, ideally the result is a normally distributed “bell” curve about a mean value. This ideal case does not necessarily hold true for all mechanical properties of interest in steel weld metals. Tensile strength measurements tend to exhibit normal behavior for a given weld metal chemical composition deposited using a reasonable consistent welding procedure, Figure 1a. However, toughness measurements are not nearly as well-behaved or predictable. In a tensile test, assuming a defect free weld, the strength measurement is based on the bulk response of the material throughout the gage length. In a Charpy V-notch (CVN) impact test, again assuming a defect free weld, the toughness measurements are controlled largely by the very local response of the material at the point of highest stress where fracture initiates just below the notch. This paper presents a detailed assessment of a C-Mn weld metal and explains how CVN toughness can vary from less than 20 ft-lbf to over 200 ft-lbf in the same weld, often with test specimens located adjacent to one another in the test weld, Figure 1b. The much localized microstructure features that give rise to this degree of variation are a combined result of chemical composition, welding procedure, pass sequence, and individual welder technique. The evidence suggests that retained austenite in coarse grained regions of the as-deposited weld metal transform to martensite at the CVN test temperature, effectively creating local brittle zones in the weld metal. This example provides basis for examination of a broader range of microstructural discontinuities in steel weld metals and their potential influence on toughness measurement.

A systematic study of the fatigue crack growth characteristics and mechanisms in AI-Si-Mg and A356 casting alloys was carried out. Compact tension specimens, prepared from modified and unmodified alloys were tested at different stress ratios and stress intensity factor range values, and a study of the mechanistic role of the silicon particles in influencing the fracture behaviour during fatigue crack propagation was made, employing both optical and scanning electron microscopy. The results indicated that the fatigue crack growth behaviour of the alloys is affected by the stress ratio, stress intensity level and the size, shape and distribution of the eutectic silicon particles. The particle characteristics also determine the fracture mode of the alloy. Fracture Characteristics observed include decohesion of the silicon particles from the aluminum matrix; silicon particle cleavage/cracking; and striations in the aluminum phase, particularly at high stress ratios.

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