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Title: Cold cracking in DC-cast high strength aluminum alloy ingots: An intrinsic problem intensified by casting process parameters
Authors: Lalpoor, M
Eskin, DG
Ruvalcaba, D
Fjaer, HG
Ten Cate, A
Ontijt, N
Katgerman, L
Keywords: Aluminum alloys;DC-casting;Cold cracking;Thermomechanical simulations;Fracture
Issue Date: 2011
Publisher: Elsevier
Citation: Materials Science and Engineering: A, 528(6), 2831 - 2842, 2011
Abstract: For almost half a century the catastrophic failure of direct chill (DC) cast high strength aluminum alloys has been challenging the production of sound ingots. To overcome this problem, a criterion is required that can assist the researchers in predicting the critical conditions which facilitate the catastrophic failure of the ingots. This could be achieved at first glance by application of computer simulations to assess the level and distribution of residual thermal stresses. However, the simulation results are only able to show the critical locations and conditions where and when high stresses may appear in the ingots. The prediction of critical void/crack size requires simultaneous application of fracture mechanics. In this paper, we present the thermo-mechanical simulation results that indicate the critical crack size distribution in several DC-cast billets cast at various casting conditions. The simulation results were validated upon experimental DC-casting trials and revealed that the existence of voids/cracks with a considerable size is required for cold cracking to occur.
Description: This is the post-print version of the final paper published in Materials Science and Engineering: A. The published article is available from the link below. Changes resulting from the publishing process, such as peer review, editing, corrections, structural formatting, and other quality control mechanisms may not be reflected in this document. Changes may have been made to this work since it was submitted for publication. Copyright @ 2011 Elsevier B.V.
ISSN: 0921-5093
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Brunel Centre for Advanced Solidification Technology (BCAST)

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