Skip to main content
Log in

Comparison of X-Ray Computed Tomography and Metallography for Determination of Pore Size

  • Published:
Metallurgist Aims and scope

The pores that occur during the casting process adversely affect the fatigue characteristics of the Al–Si alloys (silumins). The effect of casting pores under fatigue is associated with a number of factors, such as pore size, morphology, and position inside the cast part. Metallography can be used for the statistical characterization of pores. However, random two-dimensional sections through the pores fail to provide a reliable estimation of defect size without additional data analysis. This paper presents two experimental methods, namely X-ray computed tomography and metallography, which are used to characterize the size and morphology of the pores in the AlSi7Mg alloy casting. Three-dimensional data obtained by X-ray computed tomography were used to evaluate the criteria for determining the pore size based on metallographic measurements. The stress concentration resulting from the actual 3D morphology of pores was further investigated by the finite element method and compared with simplified 2D models of pores.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Fig. 1.
Fig. 2.
Fig. 3.
Fig. 4.
Fig. 5.
Fig. 6.
Fig. 7.
Fig. 8.

Similar content being viewed by others

References

  1. Q. G. Wang, D. Apelian, and D. A. Lados, “Fatigue behavior of A356-T6 aluminum cast alloys. Part I. Effect of casting defects,” J. Light Metals, 1, 73–84 (2001).

    Article  CAS  Google Scholar 

  2. M. J. Couper, A. E. Neeson, and J. R. Griffiths, “Casting defects and the fatigue behaviour of an aluminium casting alloy,” Fatigue Fract. Engng. Mater. Struct, 13, 213–27 (1990).

    Article  Google Scholar 

  3. C. M. Sonsino and J. Ziese, “Fatigue strength and applications of cast aluminium alloys with different degrees of porosity,” Intern. J. Fatigue, 15, 75–84 (1993).

    Article  CAS  Google Scholar 

  4. V. S. Rudnev, T. P. Yarovaya, P. M. Nedozorov, and Yu. N. Mansurov, “Wear-resistant oxide coatings on aluminum alloy formed in borate and silicate aqueous electrolytes by plasma electrolytic oxidation,” Prot. Met. Phys. Chem. Surf., 53, No. 3, 466–474 (2017).

    Article  CAS  Google Scholar 

  5. Yu. N. Mansurov, Yu. A. Miklin, N. A. Miklin, and A. V. Nikol’skii, “Methods and equipment for breaking down gold-containing concentrates from lean ores and mining industry waste,” Metallurgis, 62, No. 1–2, 169–175 (2018).

  6. B. Skallerud, T. Iveland, and G. Harkegard, “Fatigue life assessment of aluminum alloys with casting defects,” Eng. Fract. Mech., 44, 857–74 (1993).

    Article  Google Scholar 

  7. A. A. Dabayeh, A. J. Berube, and T. H. Topper, “An experimental study of the effect of a flaw at a notch root on the fatigue life of cast Al 319,” Intern. J. Fatigue, 20, 517–530 (1998).

    Article  CAS  Google Scholar 

  8. J.-Y. Buffiere, S. Savelli, P. H. Jouneau, E. Maire, and R. Fougeres, “Experimental study of porosity and its relation to fatigue mechanisms of model Al–Si7–Mg0.3 cast Al alloys,” Mater. Sci. Eng. A, 319, 115–126 (2001).

    Article  Google Scholar 

  9. Yu. N. Mansurov, J. U. Rakhmonov, N. V. Letyagin, and A. S. Finogeyev, “Influence of impurity elements on the casting properties of Al–Mg based alloys,” Non-Ferr. Met., 44, No. 1, 24–29 (2018).

    Google Scholar 

  10. A. A. Aksenov, Yu. N. Mansurov, D. O. Ivanov, and D. S. Kadyrova, “Foam aluminium for small business in the Far East,” Tsvetn. Metally, No. 4, 81–85 (2017).

    Google Scholar 

  11. A. I. Bezrukikh, V. N. Baranov, I. L. Konstantinov, et al., “Modeling of casting technology of large-sized ingots from deformable aluminum alloys,” Int. J. Adv. Manuf. Techn., 120, No. 1–2, 761–780 (2022).

    Article  Google Scholar 

  12. S. B. Sidelnikov, D. S. Voroshilov, M. M. Motkov, et al., “Investigation structure and properties of wire from the alloy of AL-REM system obtained with the application of casting in the electromagnetic mold, combined rolling-extruding, and drawing,” Int. J. Adv. Manuf. Techn., 114, No. 9–10, 2633–2649 (2021).

    Article  Google Scholar 

  13. Yu. N. Mansurov, A. A. Aksenov, and V. P. Reva, “Influence of the chill-mold casting process on the structure and properties of aluminum alloys with eutectic constituents,” Tsvetn. Metally, No. 5, 77–81 (2018).

    Google Scholar 

  14. H. Mayer, M. Papakyriacou, B. Zettl, and S. E. Stanzl-Tschegg, “Influence of porosity on the fatigue limit of die cast magnesium and aluminum alloys,” Intern. J. Fatigue, 25, 245–256 (2003).

    Article  CAS  Google Scholar 

  15. Y. Murakami, Metal Fatigue: Effects of Small Defects and Nonmetallic Inclusions, Elsevier Science (2002).

  16. Y. X. Gao, J. Z. Yi, P. D. Lee, and T. C. Lindley, “The effect of porosity on the fatigue life of cast aluminium-silicon alloys,” Fatigue Fract Eng. Mater Struct., 27, 559 (2004).

    Article  CAS  Google Scholar 

  17. Q. G. Wang and P. E. Jones, “Prediction of fatigue performance in aluminium shape casting containing defects,” Metal. Matls Trans B, 38, 615–621 (2007).

    Article  Google Scholar 

  18. V. S. Rudnev, P. M. Nedozorov, T. P. Yarovaya, and Yu. N. Mansurov, “Local plasma and electrochemical oxygenating on the example of AMg5 (AMr5) alloy,” Tsvetn. Metally, No. 1, 59–64 (2017).

    Google Scholar 

  19. G. Nicoletto, P. Baicchi, and R. Koneþna, “Fatigue life prediction of AlSi alloys with casting defects,” in: Procs 2nd Fatigue Symp., Leoben (2008), pp. 2–11.

  20. P. Powazka, et al., “Computed tomography – an alternative and complement to traditional metallographic investigations of porosity in cast aluminum,” in: Procs 2nd Fatigue Symp., Leoben (2008), pp. 51–66.

  21. Yu. N. Mansurov, D. S. Kadyrova, and J. Rakhmonov, “Dependence of corrosion resistance for aluminum alloys with composition increased impurity content,” Metallurgist, 62, No. 11–12, 1181–1186 (2019).

    Article  CAS  Google Scholar 

  22. Properties and Selection: Nonferrous Alloys and Special Purpose Materials, ASM Handbook. Vol. 2. USA, ASM Intern. (1990); https://doi.org/10.31399/asm.hb.v02.9781627081627.

  23. E. Ferrie, J. Y. Buffiere, and W. Ludwig, “3D characterization of the nucleation of a short fatigue crack at a pore in a cast Al alloy using high resolution synchrotron microtomography,” Intern. J. Fatigue, 27, 1215 (2005).

    Article  CAS  Google Scholar 

  24. A. A. Andreeva, S. Yu. Mansurov, D. V. Miklushevskiy, and Yu. N. Mansurov, “Model of formation of innovation process for large industrial enterprises,” Tsvetn. Metally, (3), 74–77 (2015).

    Article  Google Scholar 

  25. D. V. Miklushevskiy, S. Y. Mansurov, T. N. Piterskaya, and Yu. N. Mansurov, “Economy and innovation management of universities,” Tsvetn. Metally, (9), 6–12 (2015).

    Article  Google Scholar 

  26. E. S. Prusov, “Computed tomography for applications in three-dimensional materials science,” Fund. Issl., No. 5–2, 318–323 (2015).

  27. A. Pierret, Y. Capowiez, L. Belzunces, and C. J. Moran, “3D reconstruction and quantification of macropores using X-ray computed tomography and image analysis,” Geoderma, 106, No. 3–4, 247–271 (2002).

    Article  Google Scholar 

  28. H. Zhou, X. Peng, E. Perfect, T. Xiao, and G. Peng, “Effects of organic and inorganic fertilization on soil aggregation in an Ultisol as characterized by synchrotron-based X-ray micro-computed tomography,” Geoderma, 195–196, 23–30 (2013).

    Article  Google Scholar 

  29. A. M. Petrovic, J. E. Siebert, and P. E. Rieke, “Soil bulk density analysis in three dimensions by computed tomographic scanning,” Soil Sci. Society USA J, 46, No. 3, 445–450 (1982).

    Article  Google Scholar 

  30. S. J. Mooney, T. P. Pridmore, J. Helliwell, and M. J. Bennett, “Developing X-ray computed tomography to non-invasively image 3D root systems architecture in soil,” Plant Soil., 352, No. 1–2, 1–22 (2012).

    Article  CAS  Google Scholar 

  31. S. A. Hall, M. Bornert, J. Desrues, Y. Pannier, N. Lenoir, G. Viggiani, and P. Bésuelle, “Discrete and continuum analysis of localised deformation in sand using X-ray μCT and volumetric digital image correlation,” Geotechnique, 60, No. 5, 315–322 (2010).

    Article  Google Scholar 

  32. I. V. Yakimchuk, V. V. Abashkin, A. A. Chertova, and D. A. Korobkov, “Laboratory X-Ray Microtomgraphy of Sand Proppant Pack Under Stress,” in: 3rd Intern. Conf. on Tomography of Materials and Structures, Lund, Sweden, June 26–30 (2017).

  33. I. V. Yakimchuk, I. V. Safonov, E. P. Serkova, et al., “Ceramic proppant microstructure characterization by x-ray microtomography,” in: Bruker Micro-CT User Meeting 2018, Ghent, Belgium, April 16–19 (2018).

  34. I. G. Steward, Introduction to Fourier Optics [in Russian], Mir, Moscow (1985).

Download references

Author information

Authors and Affiliations

Authors

Corresponding author

Correspondence to R. V. Rahimov.

Additional information

Translated from Metallurg, Vol. 67, No. 6, pp. 94–100, June, 2023.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Rahimov, R.V., Abdullaev, B.A., Zhumabekov, B.S. et al. Comparison of X-Ray Computed Tomography and Metallography for Determination of Pore Size. Metallurgist 67, 839–848 (2023). https://doi.org/10.1007/s11015-023-01572-7

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11015-023-01572-7

Keywords

Navigation