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1 2009

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Ductile fracture locus of AC4CH-T6 cast aluminium alloy

Mae H., Teng X., Bai Y., Wierzbicki T.

Archives of Computational Materials Science and Surface Engineering

2009

Vol. 1, nr 2

100-105

Purpose: Cast aluminium alloys have found wide application to manufacture lighted-weight components of complex shape in automotive and aerospace industries. To improve the strength and ductility of cast aluminium alloys, it is necessary to study their fracture properties by conducting a series of tests. This study addresses calibration of ductile fracture property of the cast aluminium alloy (AC4CH-T6) made by the gravity die casting with sand mold. Design/methodology/approach: 6 round bar specimens and 6 butterfly specimens are machined from the actual cast component. The tensile tests on the smooth and notched round bar specimens are performed to calibrate the fracture strain in the range of high positive stress triaxialities. The combined loading tests on the butterfly specimens are carried out using a uniquely designed Universal Biaxial Testing Device (UBTD). These tests cover the fracture properties in the rage of low and negative stress triaxialities. Detailed finite element models of all the tests are developed. The fracture locus in the space of the effective plastic strain to fracture and the stress triaxiality are constructed in a wide rage from -1/3 to 1.0. Findings: It is found that material ductility sharply decreases with the stress triaxiality. The material ductility at the negative stress triaxiality is much higher than that in the positive stress triaxiality. Research limitations/implications: Large spread of data is observed for those tests repeated on the same loading configuration, necessitating the statistical analysis of the fracture processes. Practical implications: It is expected that such a fracture criterion would be able to correctly predict the fracture response of actual cast aluminum components under complex loading in the practical applications. Originality/value: The conventional researches focused on the material ductility at the stress triaxiality larger than +1/3. The present study showed the material ductility at the wide range of stress triaxiality from -1/3 to 1.0.