Simulation of microstructure and mechanical properties of aluminum components during casting and heat treatment

Abstract

The combination of alloy composition, metallurgy and local solidification conditions all lead to the development of locally varying microstructure and defects during the production of aluminum alloy castings. In turn, the local microstructure and defects play a critical role in determining the local mechanical properties. In this paper, the integrated modeling and simulation of the development of microstructure in aluminum alloy components from casting through heat treatment will be described. The predicted microstructure at the end of this process chain is used to predict the distribution of mechanical properties in the casting. This information can be used as input for e.g. durability calculations during the design phase of a new component. It can also be used to optimize the casting or heat treatment process to obtain the required mechanical properties using the most cost-effect manufacturing process. The use of the integrated process simulation as well as a comparison with measurements is illustrated using a prototypical cylinder head casting as an example. © Published under licence by IOP Publishing Ltd.