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Using quality mapping to predict spatial variation in local properties and component performance in Mg alloy thin-walled high-pressure die castings: an ICME approach and case study

  • Joy H ForsmarkEmail author
  • Jacob W Zindel
  • Larry Godlewski
  • Jiang Zheng
  • John E Allison
  • Mei Li
Research article

Abstract

This paper explores the use of quality mapping for the prediction of the spatial variation in local properties in thin-walled high-pressure die castings (HPDC) of the magnesium alloy AM60. The work investigates the role of casting parameters on local ductility and yield strength and presents a model for predicting local ductility and yield strength in a cast component. A design of experiment (DOE) was created to examine the role of various casting parameters on local properties such as ductility and yield strength. Over 1,200 tensile samples were excised from cast parts and tested. Casting simulations were also conducted for each experimental condition. Local properties were predicted, and the local property (quality map) model was compared with a prototype production component. The results of this model were used as input to a performance simulation software code to simulate the component-level behavior under two different loading conditions. In this study, the authors bypassed the traditional Integrated Computational Materials Engineering (ICME; process-microstructure-properties) approach in favor of a semi-empirical quality mapping approach to provide estimates of manufacturing sensitive local properties for use in process and component design.

Keywords

ICME Magnesium alloys High-pressure die casting Casting simulation 

Notes

Acknowledgements

JF would like to acknowledge Sheila Ryzyi of Ford Motor Company for assistance with tensile testing, Ari Caliskan of Ford Motor Company for assistance with the design of the component tests, and the Ford Safety Lab for the high-speed testing. JWZ and LG would like to acknowledge the support of Mag-Tec Casting in Jackson, MI for assistance with the casting trials. We acknowledge helpful discussions with and support of X. Sun, Pacific Northwest National Laboratory (Batelle Memorial Institute). We would also like to acknowledge Meridian Lightweight Technologies, Inc., for assistance with the prototype casting simulation and mechanical testing. JZ and JA wish to acknowledge the financial support of Battelle Memorial Institute and US Department of Energy under Contract No. DE-AC05-76RL01830. Their work was funded by the Department of Energy Vehicle Technologies Office under the Automotive Lightweighting Materials Program managed by William Joost.

Supplementary material

40192_2015_33_MOESM1_ESM.mp4 (384 kb)
Additional file 1: A schematic diagram of a typical cold-chamber high-pressure die cast machine.
40192_2015_33_MOESM2_ESM.mp4 (503 kb)
Additional file 2: Flow comparison of conditions I and U from the front side.
40192_2015_33_MOESM3_ESM.pptx (174 kb)
Additional file 3: Flow comparison of conditions I and U from the rear side.
40192_2015_33_MOESM4_ESM.mov (4.6 mb)
Additional file 4: Animation of condition I pole test.
40192_2015_33_MOESM5_ESM.mov (4.4 mb)
Additional file 5: Animation of condition U pole test.
40192_2015_33_MOESM6_ESM.mov (4.4 mb)
Additional file 6: Animation of condition U axial crush test.

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Copyright information

© Forsmark et al.; licensee Springer. 2015

This is an Open Access article distributed under the terms of the Creative Commons Attribution License (http://creativecommons.org/licenses/by/4.0), which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly credited.

Open AccessThis article is distributed under the terms of the Creative Commons Attribution 4.0 International License (https://creativecommons.org/licenses/by/4.0), which permits use, duplication, adaptation, distribution, and reproduction in any medium or format, as long as you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons license, and indicate if changes were made.

Authors and Affiliations

  • Joy H Forsmark
    • 1
    Email author
  • Jacob W Zindel
    • 1
  • Larry Godlewski
    • 1
  • Jiang Zheng
    • 2
  • John E Allison
    • 2
  • Mei Li
    • 1
  1. 1.Materials Research DepartmentFord Motor Company, Research and Innovation CenterDearbornUSA
  2. 2.Department of Materials Science and EngineeringUniversity of MichiganAnn ArborUSA

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