Prediction of mechanical properties of cast aluminium components at various iron contents

The simulation of microstructure and mechanical properties is of great importance as a lead in bringing the foundry process and cast materials closer to the casting designer. Prediction of the formation of the microstructure during solidification is a supporting factor for strength optimization of cast aluminium components that allows an improved performance and increased competitiveness of cast engineering components.The deformation behaviour and the integrity of cast components depends mostly on the chemical composition of the material, especially the iron content, solidification behaviour and the resulting microstructural characteristics. This paper aims to demonstrate the capabilities of microstructure and mechanical properties modelling of aluminium cast materials and components. The validation of the models includes investigation of cast cylinder head and measured microstructure and mechanical properties as well as their distributions. The effect of iron-rich compound’s morphology and fraction on the plastic deformation behaviour has been studied and modelled in terms of strain hardening exponent and strength coefficient. This approach enables the prediction of local microstructure and mechanical properties. The developed models have been implemented in a cast simulation software for simulation of the cast cylinder head.The model predictions of microstructural quantities and mechanical properties are in good agreement with experimental measurements.