Numerical Simulation of Residual Thermal Stresses in AA7050 Alloy during DC-Casting Using ALSIM5


Article Preview

Non-homogenous cooling rates and solidification conditions during DC-casting of high strength aluminum alloys result in the formation and accumulation of residual thermal stresses with different signs and magnitudes in different locations of the billet. Rapid propagation of micro-cracks in the presence of thermal stresses can lead to catastrophic failure in the solid state, which is called cold cracking. Numerical models can simulate the thermomechanical behavior of an ingot during casting and after solidification and reveal the critical cooling conditions that result in catastrophic failure, provided that the constitutive parameters of the material represent genuine as-cast properties. Simulation of residual thermal stresses of an AA7050 alloy during DC-casting by means of ALSIM5 showed that in the steady-state conditions large compressive stresses formed near the surface of the billet in the circumferential direction. Stresses changed sign on moving towards the centre of the billet and became tensile with high magnitudes in radial and transverse directions, which made the alloy prone to hot and cold cracking.



Advanced Materials Research (Volumes 89-91)

Edited by:

T. Chandra, N. Wanderka, W. Reimers , M. Ionescu






M. Lalpoor et al., "Numerical Simulation of Residual Thermal Stresses in AA7050 Alloy during DC-Casting Using ALSIM5", Advanced Materials Research, Vols. 89-91, pp. 319-324, 2010

Online since:

January 2010




[1] B. Hannart, F. Ciaalti and R. van Schalkwijk, in: Light Metals, edited by U. Mannweiler, TMS (1994), pp.879-887.

[2] Drezet J.M. and M. Rappaz, in: Light Metals, edited by J. Evans, TMS (1995), pp.941-950.

[3] Keh-Minn Chang, B. Kang: Journal of Chinese Institute of Engineers, Vol. 22 (1999), No. 1, pp.27-42.

[4] H.G. Fjaer, A. Mo, in: Light Metals, edited by C.M. Bickert, TMS (1990), pp.945-950.

[5] W. Boender, A. Burghardt, E.P. van Klaveren, and J. Rabenberg, in: Light Metals, edited by A.T. Tabereaux, TMS (2004), pp.679-684.

[6] O. Ludwig, J. -M. Drezet, B. Commet, B. Heinrich, in: Modeling of Casting, Welding and Advanced Solidification Processes, edited by C-A. Gandin and M. Bellet, TMS (2006), pp.185-192.

[7] W. Boender, A. Burghardt, in: 5 th Decennial Int. Conf. on Solidification Processing, edited by H. Jones, Sheffield, UK, 2007, pp.714-718.

[8] J. Wan, H.M. Lu, K. M. Chang, J. Harris, in: Light Metals, edited by B. Welch, TMS (1998), pp.1065-1071.

[9] K. -M. Chang, H. -M. Lu, J. Wan, in: Second Intern. Conf. on Quenching and Control of Diffusion, edited by J.F. Harris, ASM International (1996), pp.341-345.

[10] H.G. Fjaer, A. Mo, Metallurgical Transactions B, Vol. 21-B (1990), pp.1049-1061.

[11] E.E. Madsen and G.E. Fladmark, in: Numerical Solution of Partial Differential Equations, edited by G.E. Fladmark and J.G. Gram, D. Reidel Publishing Company, Dordrecht, The Netherlands (1973), pp.223-40.

DOI: 10.1007/978-94-010-2672-7_9

[12] E.E. Madsen, in: Numerical Methods in Thermal Problems, edited by R.W. Lewis and K. Morgan, Pineridge Press Limited, Swansea, United Kingdom (1979), pp.81-89.

[13] H. Fossheim and E.E. Madsen, in: Light Metals, edited by W.S. Peterson, TMS-AIME (1979), pp.695-720.

[14] E.K. Jensen and W. Schneider, in: Light Metals, edited by Christian M. Bickert, TMS-AIME (1990), pp.937-43.

[15] M. Lalpoor, D. Eskin, and L. Katgerman: submitted to 12 th International Conference on Fracture, Ottawa, Canada, (2009).

[16] B. Magnin, L. Katgerman, B. Hannart, in: Modeling of Casting, Welding and Solidification Process, edited by M. Cross and J. Campbell, Warrendale, USA (1995), pp.303-310.

[17] C.L. Martin, O. Ludwig and M. Suéry, in: Aluminum Alloys: Their Physical and Mechanical Properties, edited by P.J. Gregson and S.J. Harris, Mater. Sci. Forum, Vol. 396-402 (2002), p.265270.

[18] M. Lalpoor, D. Eskin, and L. Katgerman: Mater. Sci. Eng. A Vol. 497 (2008), pp.186-194.

In order to see related information, you need to Login.