Aleacion Al319 PDF

University of Illinois at Urbana-Champaign
Department of Mechanical and Industrial Engineering

Thermo
Thermo
-
-
Mechanical Fatigue of Cast
Mechanical Fatigue of Cast
319 Aluminum Alloys
319 Aluminum Alloys
Huseyin Sehitoglu,
1
Carlos C. Engler-Pinto Jr.
2
,
Hans J. Maier
3
,Tracy J. Foglesong
4
1
University of Illinois at Urbana- Champaign, USA,
2
Ford Motor Company, Dearborn,
3
Universitt-
GH Paderborn, Germany,
4
Exxon , Houston
Research Supported by Ford Motor Company
Use of Aluminum Alloys in engine blocks and cylinder
heads
Thermo-Mechanical Fatigue Results
Summary
Modeling Studies (Precipitation hardened aluminum
alloys)
Outline
Outline
Percentage of Vehicles with Aluminum
Percentage of Vehicles with Aluminum
Engine Blocks and Heads (*)
Engine Blocks and Heads (*)
(*) Delphi VIII Study, 1996
20% 10% 5% Light trucks
50% 30% 13% Passenger cars
Blocks
60% 40% 20% Light trucks
95% 85% 78% Passenger cars
Heads
2005 2000 1994
Advantages of cast aluminum
Advantages of cast aluminum
Lightweight
V-8 Engine Block: 150 lbs Cast Iron vs. 68 lbs
Aluminum
Cast into complex shapes
Increased thermal conductivity
Cylinder Heads
Inlet Valve Exhaust Valve
Spark Plug
Practical Application
Practical Application
Al319
Al319
-
-
T7B
T7B
Nominal Composition in weight percentage
(*) WAP319: max 0.4% Fe - EAP319: max 0.8% Fe
Thermal treatment
solutionizing at 495C for 8 hours followed by precipitating at
260C for 4 hours)
*
Fe
0.05
max
0.25
max
0.25
max
0.20-
0.30
0.25-
0.35
3.3-
3.7
7.2-
7.7
Bal.
Cr Ti Zn Mn Mg Cu Si Al
Thermo
Thermo
-
-
Mechanical Fatigue Cycles
Mechanical Fatigue Cycles
Simultaneously changing strain and
temperature (T)
In-Phase: max-strain at max-T
Out-of-Phase: max-strain at min-T
300
200
100
T
(
C
)
-1
0
1
m
e
c
h
(
%
)
6 4 2 0
time (min)
OP
IP
-1
0
1
m
e
c
h
(
%
)
300 200 100
T (C)
IP
OP
Fatigue of materials subjected to simultaneously changing
temperature and strain.

tot
=
th
+
mech
Terminology
in-phase
out-of-phase
Thermo
Thermo
-
-
Mechanical Fatigue
Mechanical Fatigue
Temp.
Mech. Strain
T
max
T
min
max
min
TMF IP TMF OP
Micro-Computer
Hydraulic
Testing
Machine
F T

T vs. t
TMF Testing
TMF Testing
pyrometer
extensometer
Induction
Heating
load cell
vs. t
Isothermal LCF
20C, 150C, 250C and 300C
210
-1
s
-1
, 410
-3
s
-1
and 510
-5
s
-1
Thermo-Mechanical Fatigue
100300C 510
-5
s
-1
Experimental Procedures
Experimental Procedures
TMF Loops
TMF Loops
-0.4 -0.2 0.0 0.2 0.4
Mechanical Strain (%)
100C
300C
1
200
In-Phase
m
= 0.54%
N
f
= 390
20
-200
-100
0
100
200
S
t
r
e
s
s
(
M
P
a
)
-0.4 -0.2 0.0 0.2 0.4
Mechanical Strain (%)
100C
300C
Cycle
1
200
1220
Out-of-Phase
m
= 0.6%
N
f
= 2460
TMF OP 100
TMF OP 100
-
-
300C 1.0%
300C 1.0%
-200
-100
0
100
200
S
t
r
e
s
s
(
M
P
a
)
-6x10
-3
-4 -2 0 2 4 6
Strain
STRESS1-2fea Stress1-2
STRESS300fea Stress300
100C
300C
200C
Fatigue Life Criterion
Fatigue Life Criterion
LCF - 250C - 0.3% - 0.5 hz
WAP319-T7B
120
80
40
0
M
a
x
i
m
u
m
S
t
r
e
s
s
(
M
P
a
)
5000 0
Number of Cycles
50% Load Drop
N
f
80
60
40
20
0
Y
i
e
l
d
S
t
r
e
n
g
t
h
(
M
P
a
)
120 100 80 60 40 20 0
time (h)
Precipitate
Precipitate
Coarsening
Coarsening
45000 cycles / ~25 hours
(300C,
m
= 0.2%).
Exposure at 300C
Initial
TMF Loops
TMF Loops
200
100
0
-100
O
P
S
t
r
e
s
s
(
M
P
a
)
-0.6 -0.4 -0.2 0.0 0.2 0.4
OP Inelastic Strain (%)
-200
-100
0
100
I
P
S
t
r
e
s
s
(
M
P
a
)
0.6 0.4 0.2 0.0 -0.2 -0.4
IP Inelastic Strain (%)
OP
IP
100C
300C
TMF
TMF

Peak Stresses
Peak Stresses
300
250
200
150
100
50
S
t
r
e
s
s
(
M
P
a
)
2 3 4 5 6 7 8 9
0.1
2 3 4 5 6 7 8 9
1
2
Inelastic Strain Range (%)
OP IP
max
-
min
100C
300C
TMF
TMF

Stress Range Evolution

Stress Range Evolution
350
300
250
200
150
100
50
S
t
r
e
s
s
R
a
n
g
e
(
M
P
a
)
2500 2000 1500 1000 500 0
Number of Cycles
TMF OP
TMF IP
EAP319-T7B
Initial Behavior
IP
N
f
/2
OP
N
f
/2
Cyclic Stress
Cyclic Stress
-
-
Strain Curves
Strain Curves
400
350
300
250
200
150
S
t
r
e
s
s
R
a
n
g
e
(
M
P
a
)
0.0001
2 3 4 5 6 7 8 9
0.001
2 3 4 5 6 7 8 9
0.01
2
Inelastic Strain Range
WAP319
TMF OP
TMF IP
EAP319
TMF OP
TMF IP
300C 0.5 hz
300C 5x10
-5
s
-1
WAP319
EAP319
TMF Life
TMF Life
0.001
2
3
4
5
6
0.01
2
3
4
5
M
e
c
h
a
n
i
c
a
l
S
t
r
a
i
n
R
a
n
g
e
10
1
10
2
10
3
10
4
10
5
10
6
10
7
10
8
Cycles to Failure
150C 40 hz
250C 40 hz
250C 0.5 hz
250C 5x10
-5
s
-1
300C 5x10
-5
s
-1
300C 0.5 hz
TMF OP
TMF IP
Room
Temperature
EAP319-T7B
TMF Life
TMF Life
400
350
300
250
200
150
100
50
S
t
r
e
s
s
R
a
n
g
e
(
M
P
a
)
10
1
10
2
10
3
10
4
10
5
10
6
10
7
10
8
Cycles to Failure
Room
Temperature
300C 5x10
-5
s
-1
TMF OP 5x10
-5
s
-1
TMF IP
5x10
-5
s
-1
300C 2x10
-3
s
-1
150C
2x10
-1
s
-1
250C
2x10
-3
s
-1
EAP319-T7B
0.0001
2
4
6
8
0.001
2
4
6
8
0.01
2
I
n
e
l
a
s
t
i
c
S
t
r
a
i
n
R
a
n
g
e
10
1
10
2
10
3
10
4
10
5
Cycles to Failure
EAP319
250C 0.5 hz
250C 5x10
-5
s
-1
300C 0.5 hz
300C 5x10
-5
s
-1
TMF OP
TMF IP
OP + LCF
IP
WAP319
TMF OP
TMF IP
TMF Life
TMF Life
EAP319
EAP319
-
-
T7B
T7B
TMF
TMF
-
-
OP
OP
100
100
300C
300C
m m
=0.6%
=0.6%
N
N
f f
=2460 c.
=2460 c.
EAP319
EAP319
-
-
T7B
T7B
TMF
TMF
-
-
IP
IP
100
100
300C
300C
m m
=0.54%
=0.54%
N
N
f f
=390 c.
=390 c.
2
3
4
5
6
7
8
9
0.01
2
3
4
5
M
e
h
a
n
i
c
a
l

S
t
r
a
i
n

R
a
n
g
e
10
1
2 3 4 5 6 7 8 9
10
2
2 3 4 5 6 7 8 9
10
3
2 3 4 5 6 7 8 9
10
4
N
f
WAP EAP Prediction
TMF-IP
TMF-OP
a
0
= 70 m
300 m
1. TMF stress-strain behavior is identical for both IP and
OP loading conditions. TMF-IP lives are shorter than
TMF-OP (based on the mechanical or inelastic strain
range) lives.
2. Creep damage dominates for TMF-IP loading and in
the high strain range regime.
3. The secondary alloy (EAP319) is softer than the
primary alloy (WAP319), but TMF lives are very
similar.
Summary
Summary
Aluminum
Aluminum
-
-
Copper Alloys
Copper Alloys
Precipitate-dislocation interactions
Anisotropy on plastic flow behavior (Hosford & Zeisloft 72, Bate et al. 81, Barlat & Liu 98,
Choi & Barlat 99)
Bauschinger effect (Abel & Ham 66, Moan & Embury 79, Wilson 65)
Coherent particles - GP zones and '' (Price and Kelly 64)
Higher yield stress than Al shearing of particles
Comparable work hardening rates and
deformation to Al
Semi-coherent - ' ( P & K 64, Russell & Ashby 70)
High yield stress and high work hardening rates
Incoherent particles - ( P & K 64, R & A 70)
Low initial yield stress
Highest rates of work hardening
Precipitate Development
Precipitate Development
GP zones * Peak aged, '
Over aged, ' & fine Very over aged, coarse
*Sato & Takahashi, 1983
Limitations of current models
Limitations of current models
No implicit consideration of aging treatment.
Models were developed for one specific aging treatment
Peak aged, '
No inclusion of length scale
Volume fraction, precipitate size, mean free path etc. with aging treatment
Empirical hardening models with a microstructural basis.
Proposed Hardening Law
Proposed Hardening Law
Single crystal formulation - one precipitate type
Polycrystal formulation
More than one type of precipitate
Incorporate grain size length scale
=
K
o
2
b
2
o
( )
d
+
o
o
|
\

|
.
|
|

(

(
(

k
k
2
b
2
o
( )
1
2
K
1
d
1
+
2
2
K
2
d
2
+
3
2
K
3
d
3
|
\

|
.
|
|
+
o
o3
|
\

|
.
|
|

(

(
(

k
k
d
3
d
1
d
2
grain
'

Constitutive Equations
Constitutive Equations
Relate stress and strain rate at single crystal and
polycrystal level.
Can be written in pseudo-linear form.
Assume overall polycrystal response described by law
similar to that of single crystal.

i
in
=

o
m
i
s
m
j
s
c
s
m
k
s

k
c
s
|
\

|
.
|
s =1
S
n1

`

)

j
wherei =1, 5

i
in
= M
ij
c(sec)
( )
j
E
i
in
= M
ij
(sec)
( )
j
Hardening with Precipitates
Hardening with Precipitates
Start with dislocation evolution equation
Combine with the Bailey-Hirsch relationship for flow stress.
=
K
o
db
+ k
1
k
2

(

(
k

k
Geometric storage term due
to boundaries / obstacles
Statistical storage of dislocations
Dynamic recovery
of dislocations
=
o
+b
500
400
300
200
100
0
S
t
r
e
s
s
,

(
M
P
a
)
20 15 10 5 0
Inelastic Strain, (%)
Solid line - Experiment
Dashed line - Simulation
Experiment and Simulation for Al - 4% Cu Single Crystals
[123] Orientation - Different Aging Conditions
190C, 24 hrs
190C, 3 hrs
No Aging
Summary
Summary
The hardening law including the effects of
precipitates on the deformation behavior of binary
Al - Cu alloys is physically based and accounts for
precipitate size, orientation, and mean free path.
The model incorporates hardening law and
predicts single crystal behavior of pure Al and Al-
Cu alloys, it also predicts polycrystalline
experiments from knowledge of single crystal
behavior.

Aleacion Al319 PDF

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Aleacion Al319 PDF

Uploaded by

Copyright:

Available Formats

University of Illinois at Urbana-Champaign

Department of Mechanical and Industrial Engineering

Stress Range Evolution

You might also like