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The Influence of Porosity and Its Modeling on Fatigue Behavior of High Pressure Die Cast Aluminum including the Effects of Mean Stress, Stress Gradient and Specimen Size

Zhang, Bohua
http://rave.ohiolink.edu/etdc/view?acc_num=toledo1556259677391458

Abstract Details

2019, Master of Science, University of Toledo, Mechanical Engineering.
High pressure die casting (HPDC) aluminum has been widely employed in many industries for its superb cast ability, productivity, flexibility and especially the high strength to weight ratio. The use of aluminum as a light metal reduces weight and the employ of HPDC aluminum enables mass production of thin-walled, complex, intricate components with near net shape. However, one disadvantage of this technology is the inevitable presence of various defects, particularly porosity. The objective of this study was to evaluate and characterize the fatigue behavior of HPDC aluminum with effects of defects. Porosity was the main defect studied. Tensile tests and load-controlled fatigue tests were conducted to generate data for this investigation. The material, A380 HPDC aluminum, was provided by Eaton Corporation, as the sponsor of this study. Tensile tests were performed to obtain basic mechanical properties of the material. Fatigue tests were performed for different conditions to characterize fatigue behavior and evaluate the effects of porosity level, specimen size, mean stress and stress gradient. Two different size specimens were tested under the same condition to evaluate the influence of specimen size on fatigue behavior, and specimens were divided into four levels according to the amount of porosity to study the effect of porosity level on fatigue behavior. As for mean stress, R = 0 tests were conducted to compare to the results of R = -1 tests and rotating bending tests were added for stress gradient evaluation. Stress-life curves were employed for generating relation between stress amplitude and fatigue life, while the significant scatter in the experimental data necessitated a statistical analysis. The fracture surfaces of failed specimens were also examined for crack initiation location and size of defects present.
Ali Fatemi (Committee Chair)
Lesley Berhan (Committee Member)
Mohamed Samir Hefzy (Committee Member)
155 p.
Mechanical Engineering
Fatigue; HPDC Al; Porosity

Recommended Citations

Citations

  • Zhang, B. (2019). The Influence of Porosity and Its Modeling on Fatigue Behavior of High Pressure Die Cast Aluminum including the Effects of Mean Stress, Stress Gradient and Specimen Size [Master's thesis, University of Toledo]. OhioLINK Electronic Theses and Dissertations Center. http://rave.ohiolink.edu/etdc/view?acc_num=toledo1556259677391458

    APA Style (7th edition)

  • Zhang, Bohua. The Influence of Porosity and Its Modeling on Fatigue Behavior of High Pressure Die Cast Aluminum including the Effects of Mean Stress, Stress Gradient and Specimen Size. 2019. University of Toledo, Master's thesis. OhioLINK Electronic Theses and Dissertations Center, http://rave.ohiolink.edu/etdc/view?acc_num=toledo1556259677391458.

    MLA Style (8th edition)

  • Zhang, Bohua. "The Influence of Porosity and Its Modeling on Fatigue Behavior of High Pressure Die Cast Aluminum including the Effects of Mean Stress, Stress Gradient and Specimen Size." Master's thesis, University of Toledo, 2019. http://rave.ohiolink.edu/etdc/view?acc_num=toledo1556259677391458

    Chicago Manual of Style (17th edition)

toledo1556259677391458
567
© 2019, some rights reserved.Creative Commons License The Influence of Porosity and Its Modeling on Fatigue Behavior of High Pressure Die Cast Aluminum including the Effects of Mean Stress, Stress Gradient and Specimen Size by Bohua Zhang is licensed under a Creative Commons Attribution-NonCommercial-NoDerivs 3.0 Unported License. Based on a work at etd.ohiolink.edu.
This open access ETD is published by University of Toledo and OhioLINK.