Residual Stresses in DC cast Aluminum Billet: Neutron Diffraction Measurements and Thermomechanical Modeling

Journal Article · Wed May 04 00:00:00 EDT 2011 · AIP Conference Proceedings

DOI:https://doi.org/10.1063/1.3589668· OSTI ID:21516704

Drezet, J -M ^[1]; Evans, A ^[2]; Pirling, T ^[3]

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1. LSMX, Ecole Polytechnique Federale de Lausanne, Station 12, CH-1015 Lausanne (Switzerland)
2. Paul Scherrer Institut, PSI, CH-5232 Villigen (Switzerland)
3. Institut Laue Langevin, ILL, F-38042 Grenoble (France)

Thermally-induced residual stresses, generated during the industrial Direct Chill casting process of aluminum alloys, can cause both significant safety concerns as well as the formation of defects during down-stream processing. Although these thermally induced strains can be partially relieved by permanent deformation, cracks will be generated either during solidification (hot tears) or post-solidification cooling (cold cracks) when stresses exceed the deformation limit of the alloy. Furthermore, the thermally induced strains result in the presence of large internal stresses within the billet before further processing steps. Although numerical models have been previously developed to compute these residual stresses, most of the computations have been validated only against measured surface distortions. In the present work, the variation in residual elastic strains and stresses in the steady state regime of casting has been measured as a function of radial position using neutron diffraction in an AA6063 grain-refined cylindrical billet. These measurements have been carried out on the same billet section at Poldi at PSI-Villigen and at Salsa at ILL-Grenoble and compare favorably. The results are used to validate a thermo-mechanical finite element casting model and to assess the level of stored elastic energy within the billet.

• OSTI ID: 21516704
• Journal Information: AIP Conference Proceedings, Vol. 1353, Issue 1; Conference: ESAFORM 2011: 14. international ESAFORM conference on material forming, Belfast, Northern Ireland (United Kingdom), 27-29 Apr 2011; Other Information: DOI: 10.1063/1.3589668; (c) 2011 American Institute of Physics; ISSN 0094-243X
• Country of Publication: United States
• Language: English

Related Subjects

36 MATERIALS SCIENCE
75 CONDENSED MATTER PHYSICS
SUPERCONDUCTIVITY AND SUPERFLUIDITY
ALUMINIUM
ALUMINIUM ALLOYS
CASTINGS
COMPARATIVE EVALUATIONS
COOLING
CRACKS
CRYSTAL DEFECTS
DEFORMATION
FINITE ELEMENT METHOD
NEUTRON DIFFRACTION
RESIDUAL STRESSES
SAFETY
SIMULATION
SOLIDIFICATION
STEADY-STATE CONDITIONS
STRAINS
STREAMS
SURFACES
ALLOYS
CALCULATION METHODS
COHERENT SCATTERING
CRYSTAL STRUCTURE
DIFFRACTION
ELEMENTS
EVALUATION
MATHEMATICAL SOLUTIONS
METALS
NUMERICAL SOLUTION
PHASE TRANSFORMATIONS
RIVERS
SCATTERING
STRESSES
SURFACE WATERS