Application of a Pore Fraction Hot Tearing Model to Directionally Solidified and Direct Chill Cast Aluminum Alloys

Dou, Ruifeng; Phillion, A.B.

doi:10.1007/s11661-016-3590-8

Cited by 10 publications

(2 citation statements)

References 26 publications

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“…However, the deformation of solids usually does not only occur in the same direction. Thus, Dou [15] introduced a strain perpendicular to the thermal gradient direction to extend the solid deformation to two dimensions. However, a certain difference between this and the deformation that occurs in three-dimensional space remains.…”

Section: Improved Rdg Criteriamentioning

confidence: 99%

Microstructure and hot tearing sensitivity simulation and parameters optimization for the centrifugal casting of Al-Cu alloy

Lv,

Dou,

et al. 2023

Preprint

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A mathematical model of horizontal centrifugal casting was established, and numerical simulation analysis was conducted for the centrifugal casting process of cylindrical Al-Cu alloy castings to investigate the effect of the centrifugal casting process conditions on the microstructure and hot tearing sensitivity of alloy castings. Results show that increasing the centrifugal rotation and pouring speeds can refine the microstructure of the alloy but increasing the pouring and mold preheating temperatures can lead to an increase in grain size. The grain size gradually transitions from fine grain on the outer layer to coarse grain on the inner layer. Meanwhile, combined with the modified RDG hot tearing criterion, the overall distribution of the castings’ hot tearing sensitivity was analyzed. The analysis results indicate that the porosity in the middle region of the casting was large, and hot tearing defects were prone to occur. The hot tearing tendency on the inner side of the casting was greater than that on the outer side. The effects of centrifugal rotation speed, pouring temperature, and preheating temperature on the thermal sensitivity of Al-Cu alloy castings are summarized in this paper. This study revealed that the tendency of alloy hot cracking decreases with the increase of the centrifugal speed, and the maximum porosity of castings decreases first and then increases with the pouring temperature. As the preheating temperature increases, the overall maximum porosity of castings shows a decreasing trend.

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Section: Improved Rdg Criteriamentioning

confidence: 99%

Microstructure and hot tearing sensitivity simulation and parameters optimization for the centrifugal casting of Al-Cu alloy

Lv,

Dou,

et al. 2023

Preprint

Self Cite

View full text Add to dashboard Cite

show abstract

“…Monroe and Beckermann [14,15] predicted hot tearing tendency of alloys using a dimensionless Niyama criterion, the results indicated that deformation pores under tension can result in the increase of the quantity and the volume of shrinkage pores, thus increasing the hot tearing tendency of alloys. Dou and Phillion [16] added the strain rate parallel with the thermal gradient to a pressure drop equation on the basis of the dimensionless Niyama criterion, which demonstrated that an increase in casting speed increased both the deformation and shrinkage pore fractions, resulting in an increase in the probability of hot tearing. The studies above show that the heterogeneous defects in casting have significant impact on the formation and propagation of hot tearing, which is an important factor needed to be considered in hot tearing analysis.…”

Section: Introductionmentioning

confidence: 99%

Mechanism for the induction and enhancement of inclusions on crack source and simulation analysis for hot tearing tendency of aluminum alloy

You¹,

Rao²,

Wen³

et al. 2022

Modelling Simul. Mater. Sci. Eng.

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Inclusions are typical discontinuous defects, those defects significantly reduce the local mechanical properties of castings during solidification, and play a strong role in inducing and enhancing hot tearing in alloys. Based on the coupling characterization of micro solidification morphology and macro inclusions, this paper proposed a construction method of heterogeneous model containing multi-scale information, and carried out dynamic analysis on the evolution process of stress field at the end of solidification, so as to investigate the influence mechanism of inclusions on the initiation and propagation of hot tearing. The results showed that inclusions and their local content significantly changed the stress field at the end of solidification, which easily resulted in local stress concentration and induced crack source in defects area. During the crack propagation, nearby inclusions greatly reduced the propagation resistance and promoted the formation of hot tearing, which had significant impact on the propagation path of hot tearing. Introducing inclusions defect into stress analysis and comprehensively considering the induction and enhancement of inclusions on hot tearing can better improves the prediction accuracy of hot tearing, which has engineering guiding significance for casting process optimization and product quality control.

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A Study on Hot Tearing in Direct Chill Casting of Al-Mn-Mg Alloys Using a Multi-scale Approach

Khodaei

Phillion

2021

Metall Mater Trans B

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A multi-scale approach for simulating hot tearing during the DC casting of aluminum alloys is presented. The novelty of this approach lies in the combination of a macro-scale finite element simulation of the DC casting process with direct prediction of hot tears via a meso-scale multiphysics granular model. This approach is capable of simulating hot tearing initiation, growth, and propagation within a representative volume element of the mushy zone. The change of cooling conditions experienced by the DC cast billet as a result of variations in casting speed as well as non-uniformity of heat extraction from different locations of the billet affect the deformation state, cooling rate, and thermal gradient, which further influence the strain rate, grain size, permeability, and feeding coefficient. Considering all the mentioned parameters, the multi-scale approach emphasizes the fact that hot tearing is a phenomenon resulting from the combination of the tensile deformation and restricted feeding of the mushy zone. The developed hot tearing formation maps identify the locations where hot tearing will occur as predicted by the multi-scale approach for two alloys -AA5182 and AA3104 -thus demonstrating the approach's sensitivity to both processing parameters and alloy composition.

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Application of a Pore Fraction Hot Tearing Model to Directionally Solidified and Direct Chill Cast Aluminum Alloys

Cited by 10 publications

References 26 publications

Microstructure and hot tearing sensitivity simulation and parameters optimization for the centrifugal casting of Al-Cu alloy

Microstructure and hot tearing sensitivity simulation and parameters optimization for the centrifugal casting of Al-Cu alloy

Mechanism for the induction and enhancement of inclusions on crack source and simulation analysis for hot tearing tendency of aluminum alloy

A Study on Hot Tearing in Direct Chill Casting of Al-Mn-Mg Alloys Using a Multi-scale Approach

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