Microstructural modelling for the prediction of tensile strength and elongation in automotive aluminium alloy castings

摘要

Aluminium castings are increasingly used as an alternative to steel and cast iron due to the weight savings. This is especially important in the automotive industry where the energy and environmental benefits are crucial. Computer simulation is facilitating the use of aluminium castings throughout the design and production processes, including casting simulations to optimise process yield and minimize defects. A multiscale model for correlating processing conditions to microstructure and hence mechanical properties is presented and applied to virtual design an automotive part, first at a macroscopic, then a microscopic level. The microstructure is simulated using a novel Cellular Automata-Finite Difference (CAFD) model and the defect levels it predicts are linked via empirical formulations to estimate the final mechanical properties for an A356-T6 (AC4CH) alloy. The simulation results are compared with results obtained from laboratory scale wedge castings and industrial brake-caliper castings.