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Technical Paper

Fatigue Tests of Un-Notched and Notched Specimens and Life Prediction Using a Variable Critical Distance Method

2019-04-02
2019-01-0801
Fatigue is one of the most common failure mechanism in engineering structures. The statistical nature of fatigue life and the stress gradient are the two challenges among many while designing any component or structure for fatigue. Fatigue lives of the identical components exhibit the considerable variation under the same loading and operating conditions due to the difference in the material micro-structures and other uncontrolled parameters. Stress concentration at the notch causes stress gradient and therefore, applying the plane specimen results for actual engineering components with notches does not give quantitatively reliable results if the stress gradient effects are not considered. The objective of the work presented here was to carry out the fatigue tests of un-notched, U and V-notch specimens which were die cast using aluminum alloy (A380) and to obtain fatigue life using a variable critical distance method which considers the stress gradient due to the notch geometry.
Technical Paper

Prediction of Secondary Dendrite Arm Spacing in Directional Solidification of Aluminum Alloy by Casting Simulation and Micro-Structural Inspection

2019-01-09
2019-26-0166
In automotive industry, many of the powertrain components (for e.g. engine head and cylinder block) are generally manufactured by a casting procedure. Secondary Dendrite Arm Spacing (SDAS) is one of the most important microstructural features in dendritic solidification of alloys (for e.g. Al-Si alloys) during the casting process. SDAS has a significant influence on the mechanical behavior of the cast aluminum components. A lower value of SDAS is desired in order to achieve better fatigue strength of the cast components which can be controlled by governing several casting parameters. For directional solidification, SDAS is dependent on various casting parameters i.e. chemical composition of the alloy, cooling rate and liquid melt treatment. During industrial casting of an alloy with predefined chemical composition, cooling rate during the mushy zone becomes the dominant parameter for controlling SDAS.
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