A Validated Through Process Model to Predict the Fatigue Life of a Cast A356 Automotive Wheel

Abstract:

Models describing the critical steps in the manufacturing process of aluminum alloy wheels were integrated with a model of in-service loading to predict component fatigue performance. A multiscale solidification model was coupled with models of the subsequent heat treatment and machining to predict the residual stress distribution in a finished wheel. A second multiscale model was incorporated into a service model to relate the pore size and local stress state to fatigue performance. The predictions resulting from this through process modeling approach have been validated by comparisons with a series of measurements: 1) thermocouple measurements during casting; 2) characterization of pore size and distribution using X-ray microtomography and optical metallography; 3) residual strain measurements on finished wheels; 4) in-service strain measurements during a rotating bend test; and 5) in-service fatigue performance during rotating bend tests.

• Periodical: Materials Science Forum (Volumes 519-521)
• Pages: 1777-1782
• DOI: https://doi.org/10.4028/www.scientific.net/MSF.519-521.1777
• Online since: July 2006
• Authors: Peter D. Lee, Pei Feng Li, Daan M. Maijer, Trevor C. Lindley
• Keywords: Aluminum (Al), Casting, Fatigue, Heat Treatment, Modeling

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