An integrated two-dimensional modeling method for predicting ductility of thin-walled die cast magnesium

Choi, Kyoo Sil; Barker, Erin I.; Sun, Xin; Song, Jie; Xiong, Shou-Mei; Forsmark, Joy; Li, Mei

doi:10.1007/s10704-019-00390-w

Title: An integrated two-dimensional modeling method for predicting ductility of thin-walled die cast magnesium

Journal Article · 10 October 2019 · International Journal of Fracture

DOI: https://doi.org/10.1007/s10704-019-00390-w · OSTI ID:1570892

Choi, Kyoo Sil ^[1]; Barker, Erin I. ^[1];

^[2]; Song, Jie ^[3]; Xiong, Shou-Mei ^[4]; Forsmark, Joy ^[5]; Li, Mei ^[5]

Pacific Northwest National Lab. (PNNL), Richland, WA (United States)
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Purdue Univ., West Lafayette, IN (United States)
Tsinghua Univ., Beijing (People’s Republic of China)
Ford Motor Co., Dearborn, MI (United States)

In this paper, a two-dimensional (2D) microstructure-based modeling method is developed in order to predict the ductility of a thin-walled high pressure die cast magnesium (Mg) by considering the three-dimensional (3D) thru-thickness pore distributions. For this purpose, a series of 3D synthetic microstructure-based finite element models and the corresponding 2D models are first generated with various pore volume fractions, pore size distributions and pore shapes. The input material properties for the 2D models are determined based on the 3D cubic model with a spherical pore and the generalized Neuber’s rule. Based on the resulting ductility of the 3D and 2D models, a 3D/2D ductility correlation curve is developed as a function of the characteristics/shape of the input fracture strain curve used in the 3D model. The validity of the ductility correlation curve is examined with casting samples with actual microstructures. Here, the results show that the suggested 2D modeling methodology can be used together with the ductility correlation curve in predicting the ductility of thin-walled Mg castings.

View Accepted Manuscript (DOE)

Cite

Export

Save

Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE)

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 1570892

Journal Information:: International Journal of Fracture, Journal Name: International Journal of Fracture Journal Issue: 1; ISSN 0376-9429

Publisher:: SpringerCopyright Statement

Country of Publication:: United States

Language:: English

References (36)

Tensile properties of high-pressure die-cast AM60 and AZ91 magnesium alloys on microporosity variation Lee, Choong Do Journal of Materials Science, Vol. 42, Issue 24 https://doi.org/10.1007/s10853-007-2003-1	journal	December 2007
The Role of Microstructure on Ductility of Die-Cast AM50 and AM60 Magnesium Alloys Chadha, Gurjeev; Allison, John E.; Jones, J. Wayne Metallurgical and Materials Transactions A, Vol. 38, Issue 2 https://doi.org/10.1007/s11661-006-9027-z	journal	February 2007
The Influence of Al Content and Thickness on the Microstructure and Tensile Properties in High-Pressure Die Cast Magnesium Alloys Deda, Erin; Berman, Tracy D.; Allison, John E. Metallurgical and Materials Transactions A, Vol. 48, Issue 4 https://doi.org/10.1007/s11661-017-3958-4	journal	January 2017
Tensile instability and necking in materials with strain hardening and strain-rate hardening Ghosh, A. K. Acta Metallurgica, Vol. 25, Issue 12 https://doi.org/10.1016/0001-6160(77)90072-4	journal	December 1977
Effect of macro-porosity on the strength and ductility of cast Al7Si0.3Mg alloy Surappa, M. K.; Blank, E.; Jaquet, J. C. Scripta Metallurgica, Vol. 20, Issue 9 https://doi.org/10.1016/0036-9748(86)90049-9	journal	September 1986
The deformation and fracture behaviour of an AlSiMg casting alloy Cáceres, C. H.; Davidson, C. J.; Griffiths, J. R. Materials Science and Engineering: A, Vol. 197, Issue 2 https://doi.org/10.1016/0921-5093(94)09775-5	journal	July 1995
On the effect of macroporosity on the tensile properties of the Al-7%Si-0.4%Mg casting alloy Cáceres, C. H. Scripta Metallurgica et Materialia, Vol. 32, Issue 11 https://doi.org/10.1016/0956-716X(95)00031-P	journal	June 1995
Influence of porosity on the fatigue limit of die cast magnesium and aluminium alloys Mayer, H.; Papakyriacou, M.; Zettl, B. International Journal of Fatigue, Vol. 25, Issue 3 https://doi.org/10.1016/S0142-1123(02)00054-3	journal	March 2003
Magnesium Mordike, B. L.; Ebert, T. Materials Science and Engineering: A, Vol. 302, Issue 1 https://doi.org/10.1016/S0921-5093(00)01351-4	journal	April 2001
Casting defects and the tensile properties of an AlSiMg alloy Cáceres, C. H.; Selling, B. I. Materials Science and Engineering: A, Vol. 220, Issue 1-2 https://doi.org/10.1016/S0921-5093(96)10433-0	journal	December 1996
Development of the as-cast microstructure in magnesium–aluminium alloys Dahle, Arne K.; Lee, Young C.; Nave, Mark D. Journal of Light Metals, Vol. 1, Issue 1 https://doi.org/10.1016/S1471-5317(00)00007-9	journal	February 2001
Microstructure based modeling of β phase influence on mechanical response of cast AM series Mg alloys Barker, E. I.; Choi, K. S.; Sun, X. Computational Materials Science, Vol. 92 https://doi.org/10.1016/j.commatsci.2014.03.010	journal	September 2014
Calibration and evaluation of seven fracture models Wierzbicki, Tomasz; Bao, Yingbin; Lee, Young-Woong International Journal of Mechanical Sciences, Vol. 47, Issue 4-5 https://doi.org/10.1016/j.ijmecsci.2005.03.003	journal	April 2005
The correlation between microstructure and mechanical properties of high-pressure die-cast AM50 alloy Song, Jie; Xiong, Shou-Mei; Li, Mei Journal of Alloys and Compounds, Vol. 477, Issue 1-2 https://doi.org/10.1016/j.jallcom.2008.11.040	journal	May 2009
Modeling the tensile failure of cast magnesium alloys Weiler, J. P.; Wood, J. T. Journal of Alloys and Compounds, Vol. 537 https://doi.org/10.1016/j.jallcom.2012.05.090	journal	October 2012
Quantitative fractographic analysis of variability in tensile ductility of a squeeze cast Al–Si–Mg base alloy Gokhale, A. M.; Patel, G. R. Materials Characterization, Vol. 54, Issue 1 https://doi.org/10.1016/j.matchar.2004.10.003	journal	January 2005
Relationship between internal porosity and fracture strength of die-cast magnesium AM60B alloy Weiler, J. P.; Wood, J. T.; Klassen, R. J. Materials Science and Engineering: A, Vol. 395, Issue 1-2 https://doi.org/10.1016/j.msea.2004.12.042	journal	March 2005
Effect of process parameters on porosity distributions in high-pressure die-cast AM50 Mg-alloy Lee, S. G.; Gokhale, A. M.; Patel, G. R. Materials Science and Engineering: A, Vol. 427, Issue 1-2 https://doi.org/10.1016/j.msea.2006.04.082	journal	July 2006
Quantitative fractographic analysis of variability in the tensile ductility of high-pressure die-cast AE44 Mg-alloy Lee, S. G.; Patel, G. R.; Gokhale, A. M. Materials Science and Engineering: A, Vol. 427, Issue 1-2 https://doi.org/10.1016/j.msea.2006.04.108	journal	July 2006
Dependence of tensile properties of AM60 magnesium alloy on microporosity and grain size Lee, Choong Do Materials Science and Engineering: A, Vol. 454-455 https://doi.org/10.1016/j.msea.2006.11.064	journal	April 2007
Modeling fracture properties in a die-cast AM60B magnesium alloy I—Analytical failure model Weiler, J. P.; Wood, J. T. Materials Science and Engineering: A, Vol. 527, Issue 1-2 https://doi.org/10.1016/j.msea.2009.08.060	journal	December 2009
Modeling fracture properties in a die-cast AM60B magnesium alloy II—The effects of the size and location of porosity determined using finite element simulations Weiler, J. P.; Wood, J. T. Materials Science and Engineering: A, Vol. 527, Issue 1-2 https://doi.org/10.1016/j.msea.2009.08.061	journal	December 2009
Predicting the influence of pore characteristics on ductility of thin-walled high pressure die casting magnesium Sun, X.; Choi, K. S.; Li, D. S. Materials Science and Engineering: A, Vol. 572 https://doi.org/10.1016/j.msea.2013.02.026	journal	June 2013
Variability in the tensile ductility of high-pressure die-cast AM50 Mg-alloy Lee, S. G.; Patel, G. R.; Gokhale, A. M. Scripta Materialia, Vol. 53, Issue 7 https://doi.org/10.1016/j.scriptamat.2005.06.002	journal	October 2005
Prediction of tensile ductility in porous materials Jung, I. Y. Philosophical Magazine A, Vol. 82, Issue 11 https://doi.org/10.1080/01418610208235737	journal	July 2002
A Generalized Method for Estimating Multiaxial Elastic-Plastic Notch Stresses and Strains, Part 1: Theory Hoffmann, M.; Seeger, T. Journal of Engineering Materials and Technology, Vol. 107, Issue 4 https://doi.org/10.1115/1.3225814	journal	October 1985
A Generalized Method for Estimating Multiaxial Elastic-Plastic Notch Stresses and Strains, Part 2: Application and General Discussion Hoffmann, M.; Seeger, T. Journal of Engineering Materials and Technology, Vol. 107, Issue 4 https://doi.org/10.1115/1.3225815	journal	October 1985
Influence of Strain Rate and Stress State on the Mechanical Behavior of Die-Casting AM60 Magnesium Alloy Gu, Gongyao; Lin, Shaoting; Meng, Yan ASME 2011 International Mechanical Engineering Congress and Exposition, Volume 8: Mechanics of Solids, Structures and Fluids; Vibration, Acoustics and Wave Propagation https://doi.org/10.1115/IMECE2011-65196	conference	August 2012
Simple formulae for the stress concentration factor for two- and three-dimensional holes in finite domains Wang, Q. Z. The Journal of Strain Analysis for Engineering Design, Vol. 37, Issue 3 https://doi.org/10.1243/0309324021515014	journal	April 2002
A comprehensive failure model for crashworthiness simulation of aluminium extrusions Hooputra, H.; Gese, H.; Dell, H. International Journal of Crashworthiness, Vol. 9, Issue 5 https://doi.org/10.1533/ijcr.2004.0289	journal	September 2004
Fracture Modeling of AHSS in Component Crush Tests Chen, Guofei; Shi, Ming F.; Tyan, Tau SAE International Journal of Materials and Manufacturing, Vol. 4, Issue 1 https://doi.org/10.4271/2011-01-0001	journal	April 2011
An Engineering Approach to Predict Fracture and Tearing Wang, Kangping; Deng, Yih-Charng; Rao, Varun SAE 2011 World Congress & Exhibition, SAE Technical Paper Series https://doi.org/10.4271/2011-01-0002	conference	April 2011
A Mixed-Mode Fracture Criterion for AHSS Cracking Prediction at Large Strain Zhu, Hong; Zhu, Xinhai SAE International Journal of Materials and Manufacturing, Vol. 4, Issue 1 https://doi.org/10.4271/2011-01-0007	journal	April 2011
Effects of Pore Distributions on Ductility of Thin-Walled High Pressure Die-Cast Magnesium Choi, Kyoo Sil; Li, Dongsheng; Sun, Xin SAE 2013 World Congress & Exhibition, SAE Technical Paper Series https://doi.org/10.4271/2013-01-0644	conference	April 2013
An Investigation of the Effects of Cast Skin on the Mechanical Properties of an AM60 Die-Cast Magnesium Alloy Forsmark, Joy Hines; Dowling, Zachary; Gibson, Kelsey SAE International Journal of Materials and Manufacturing, Vol. 8, Issue 3 https://doi.org/10.4271/2015-01-0510	journal	January 2015
Predicting Stress vs. Strain Behaviors of Thin-Walled High Pressure Die Cast Magnesium Alloy with Actual Pore Distribution Choi, Kyoo Sil; Barker, Erin; Cheng, Guang SAE International Journal of Materials and Manufacturing, Vol. 9, Issue 2 https://doi.org/10.4271/2016-01-0290	journal	January 2016

Similar Records

An integrated two-dimensional modeling method for predicting ductility of thin-walled die cast magnesium

Journal Article · 2019 · International Journal of Fracture · OSTI ID:1572889

Choi, Kyoo Sil; Barker, Erin I.; Sun, Xin; +4 more

Effects of Pore Distributions on Ductility of Thin-Walled High Pressure Die-Cast Magnesium

Conference · 2013 · OSTI ID:1203930

Choi, Kyoo Sil; Li, Dongsheng; Sun, Xin; +2 more

Predicting the Influence of Pore Characteristics on Ductility of Thin-Walled High Pressure Die Casting Magnesium

Journal Article · 2013 · Materials Science and Engineering. A. Structural Materials: Properties, Microstructure and Processing, 572:45-55 · OSTI ID:1094937

Sun, Xin; Choi, Kyoo Sil; Li, Dongsheng

Related Subjects

36 MATERIALS SCIENCE
Ductility
Finite element analysis (FEA)
Fracture strain
Mg castings
Microstructure
Porosity

Title: An integrated two-dimensional modeling method for predicting ductility of thin-walled die cast magnesium

Citation Formats

References (36)

Similar Records

Related Subjects