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Constitutive Modeling and Thermomechanical Fatigue Life Predictions of A356-T6 Aluminum Cylinder Heads Considering Ageing Effects

  • Cast aluminum alloys are frequently used as materials for cylinder head applications in internal combustion gasoline engines. These components must withstand severe cyclic mechanical and thermal loads throughout their lifetime. Reliable computational methods allow for accurate estimation of stresses, strains, and temperature fields and lead to more realistic Thermomechanical Fatigue (TMF) lifetimeCast aluminum alloys are frequently used as materials for cylinder head applications in internal combustion gasoline engines. These components must withstand severe cyclic mechanical and thermal loads throughout their lifetime. Reliable computational methods allow for accurate estimation of stresses, strains, and temperature fields and lead to more realistic Thermomechanical Fatigue (TMF) lifetime predictions. With accurate numerical methods, the components could be optimized via computer simulations and the number of required bench tests could be reduced significantly. These types of alloys are normally optimized for peak hardness from a quenched state that maximizes the strength of the material. However due to high temperature exposure, in service or under test conditions, the material would experience an over-ageing effect that leads to a significant reduction in the strength of the material. To numerically account for ageing effects, the Shercliff & Ashby ageing model is combined with a Chaboche-type viscoplasticity model available in the finite-element program ABAQUS by defining field variables. The constitutive model with ageing effects is correlated with uniaxial cyclic isothermal tests in the T6 state, the overaged state, as well as thermomechanical tests. On the other hand, the mechanism-based TMF damage model (DTMF) is calibrated for both T6 and over-aged state. Both the constitutive and the damage model are applied to a cylinder head component simulating several cycles on an engine dynamometer test. The effects of including ageing for both models are shown.show moreshow less

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Author:Thomas SeifertORCiDGND, Radwan Hazime, Cherng-Chi Chang, Chao Hu
Year of Publication:2019
Language:English
GND Keyword:Materialermüdung; Mikrostruktur; Plastizität
Tag:thermomechanische Ermüdung
DDC classes:600 Technik, Medizin, angewandte Wissenschaften
Parent Title (English):SAE Technical Papers
Issue:2019-01-0534
ISSN:0148-7191
First Page:1
Last Page:10
Document Type:Article (reviewed)
Institutes:Bibliografie
Open Access:Zugriffsbeschränkt
Release Date:2019/12/07
Licence (German):License LogoEs gilt das UrhG
URL:https://www.sae.org/publications/technical-papers/content/2019-01-0534/
DOI:https://doi.org/10.4271/2019-01-0534