Numerical prediction of fatigue life of an A356-T6 alloy wheel considering the influence of casting defect and mean stress

Duan, Yongchuan; Zhang, Fangfang; Yao, Dan; Tian, Lihui; Liu, Yang; Guan, Yaping; Hu, Jinhua

doi:10.1016/j.engfailanal.2020.104903

Cited by 19 publications

(4 citation statements)

References 18 publications

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“…Aluminum alloys, known for superior castability, lightweight, low thermal expansion coefficient, and excellent corrosion resistance, are widely used in the automotive industry [1][2][3]. Among them, A356 alloy is a commonly used material for wheel manufacturing.…”

Section: Introductionmentioning

confidence: 99%

Effect of Al-Sr-Y intermediate alloy on microstructure and mechanical properties of A356 alloy

Huang,

Li,

Yuan

et al. 2024

Mater. Res. Express

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In this experiment, an intermediate alloy (Al-3Sr-8Y) that can refine and modify A356 alloy simultaneously was developed, and the synergistic effect of Sr and Y on the microstructure and mechanical properties of A356 alloy was investigated. The results show that when the content of Al-3Sr-8Y intermediate alloy reaches 0.3 wt.%, the morphology of α-Al dendrites is significantly refined and the secondary dendrite arm spacing (SDAS) was significantly reduced. Moreover, the morphology of eutectic Si transforms from acicular to small fibrous, and the average area and aspect ratio of eutectic Si decrease to 0.81 μm2, and 2.01. This change is caused by the twin plane re-entrant edge (TPRE) poisoning mechanism, where the addition of Al-3Sr-8Y can poison the intrinsic growth position of the Si phase, reduce the growth rate of the Si phase, promote isotropic growth, and achieve a highly branched morphology of the Si phase to form a fibrous structure. Due to the excellent synergistic effect of Sr and Y, the tensile strength and elongation of the alloy reached the maximum values of 303.5 MPa and 9.5% when 0.3 wt.% Al-3Sr-8Y was added after heat treatment, which is an increase of 18.2% and 86.3% compared with the untreated A356 alloy, respectively.

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Section: Introductionmentioning

confidence: 99%

Effect of Al-Sr-Y intermediate alloy on microstructure and mechanical properties of A356 alloy

Huang,

Li,

Yuan

et al. 2024

Mater. Res. Express

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show abstract

“…10,11 At present, the research on the fatigue properties of cast and spin aluminum alloy is relatively small, and people focus on the cast aluminum alloy wheels. [12][13][14] Ben et al 15 shown that in addition to defects such as holes, the secondary dendrite arm spacing (SDAS) will also have a significant impact on the fatigue properties of A356 aluminum alloy; Haskel et al 16 pointed that fatigue crack propagation is influenced by eutectic Si particles and that the fracture profile may be associated with the Si morphology; Yang et al 17 studied the fatigue behavior of cast A356 with different dendrite sizes, they consider that the effects of microstructure coarsening on the tensile and fatigue properties are mainly presented in the crack initiation process, followed by the crack propagation paths. The microcrack is more easier to initiate in those aggregated eutectic regions due to the high stress concentrations.…”

Section: Introductionmentioning

confidence: 99%

Casting and spinning aluminum alloy wheel fatigue properties and life prediction study

Zhang,

Song,

Yan

et al. 2023

Fatigue Fract Eng Mat Struct

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To accurately predict the fatigue life of cast aluminum alloy wheels, based on the results of finite element calculation and simulation, this work selected the rim area, inner flange and spoke areas to conduct systematic tensile and high‐cycle fatigue tests. The results show that the tensile properties of A356‐T6 cast aluminum alloy wheels are similar in various areas, but the fatigue properties are significantly different. Plastic deformation can improve the fatigue strength of the aluminum alloy, but the fatigue properties are also affected by deformation uniformity and other factors. Based on the difference of mechanical properties in different areas, this study also selected the characteristic loading spectrum to predict the fatigue life of wheels. A linear and a nonlinear damage accumulation were employed. The above methods are not only applicable to the wheel, but also provides a new idea for the life prediction of key parts in the engineering field.

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“…Lightweight is an effective measure to achieve energy saving and emission reduction and enhance sustainable performance of automobiles, and wheels are important parts of vehicles, which are related to the power, braking and comfort of automobiles. 1,2 Generally, wheels work under random alternating load, fatigue life is an important performance of wheels. From a safety point of view, in order to ensure the safety of vehicles, the wheels must have sufficient strength, stiffness and fatigue durability.…”

Section: Introductionmentioning

confidence: 99%

Fatigue life optimization and lightweight design of wheel based on entropy weight grey relation analysis and modified NSGA-II

Zhang,

Lu,

et al. 2023

Advances in Mechanical Engineering

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In order to study the fatigue performance of wheel and enhance its lightweight design level, this article proposes the structure, design and optimization method of magnesium-aluminum alloy assembled wheel. Taking a [Formula: see text] type wheel as the research object, the optimal topology of wheel spoke is solved by constructing a topology optimization model for wheel bending and radial fatigue test conditions. A finite element model for bending and radial fatigue testing of assembled wheels was established, which simulates and analyzes the fatigue performance and its influencing factors of the wheel under two working conditions. Combined with contribution analysis method, the modified NSGA-II and entropy weight grey relation analysis (EGRA), the multi-objective optimization of assembled wheel was performed. The result demonstrated that the weight reduction of the assembled wheel after optimized design is 4.49%, while the bending fatigue life and radial fatigue safety factor are decreased by 9.95% and 25%, respectively. In order to better balance the performance of assembled wheel and achieve lightweight design, this article combines the joint topology optimization of assembled wheels with multi-objective optimization method for multiple working conditions and screens the optimal compromise solution by EGRA, which provides an approach for wheel lightweight design and multi-objective optimization.

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Numerical prediction of fatigue life of an A356-T6 alloy wheel considering the influence of casting defect and mean stress

Cited by 19 publications

References 18 publications

Effect of Al-Sr-Y intermediate alloy on microstructure and mechanical properties of A356 alloy

Effect of Al-Sr-Y intermediate alloy on microstructure and mechanical properties of A356 alloy

Casting and spinning aluminum alloy wheel fatigue properties and life prediction study

Fatigue life optimization and lightweight design of wheel based on entropy weight grey relation analysis and modified NSGA-II

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