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New quality assessment criterion of AlSi5Cu1 alloy

Wierzbińska M., Sieniawski J.

Archives of Foundry Engineering

2007

Vol. 7, iss. 3

217-222

The paper presents the discussion of the results of mechanical testing for aluminium foundry alloy AlSi5Cu1Mg for high-loaded machine elements. Values of yield strength (Rp0.2), tensile strength (Rm), elongation(A5) and hardness (HB) are usually considered as the primary quality assessment criterion for a manufacturing process. It was concluded, that this criterion, A5 index particularly, is unsatisfactory to estimate the plasticity of the alloy and its crack resistance in the presence of sharp-pointed stress concentrators or microcracks. More adequate parameter is plane strain fracture toughness K_Ic. However, size of the samples appeared to be twice as large as would be needed to fulfill requirements of test conditions, and the test itself is laborious and time-consuming that it becomes impractical as a acceptance test. Therefore, substitute test for quality assessment - determination of tensile strength in the presence of a sharp notch kmR was applied. The comparative analysis of kmR/Rp0.2 ratio, as a more enhanced fatigue resistance criterion than kmR and plane strain fracture toughness K_Ic of the alloy was performed. It was assumed that kmR/Rp0.2 parameter has good correlation with the critical stress intensity factor K_Ic Thus, under manufacturing process conditions, being unable to carry out K_Ic test, it may be successfully replaced by kmR test.