Fatigue Design with High Pressure Die Cast Aluminum Including the Effects of Defects, Section Size, Stress Gradient, and Mean Stress
Abstract
Defects in metallic components can be formed in many manufacturing techniques, including casting, additive manufacturing, and powder metallurgy. These imperfections can significantly affect the mechanical properties, especially fatigue behavior of industrial components. Therefore, it is necessary to evaluate these defects and study their effect on the final mechanical performance of the components. In this study, the effect of defects on fatigue behavior of cast A356-T6 aluminum alloy, as an illustrative material, was investigated. Fatigue tests were conducted under different loading conditions to investigate the effects of defects, specimen size, mean stress and stress gradient. To achieve this goal, fully-reversed uniaxial fatigue tests were conducted on two specimen sizes, as well as tension-tension fatigue tests to study mean stress effect. Rotating bending tests were also performed to study the effect of stress gradient on fatigue performance of materials containing defects. The scatter in fatigue life data was evaluated using statistical analysis. Good correlations of the fatigue life of the specimens under different stress ratios were obtained using a mean stress correction factor. The fatigue life of the specimens under different testing conditions were also estimated using the maximum defect size observed on fracture surfaces.
Publication Title
Materials Today Communications
Recommended Citation
Nourian-Avval, A., & Fatemi, A. (2020). Fatigue Design with High Pressure Die Cast Aluminum Including the Effects of Defects, Section Size, Stress Gradient, and Mean Stress. Materials Today Communications, 25 https://doi.org/10.1016/j.mtcomm.2020.101567
