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Two-Phase Modeling of Hot Tearing in Aluminum Alloys: Applications of a Semicoupled Method

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Abstract

Hot tearing formation in both a classical tensile test and during direct chill (DC) casting of aluminum alloys has been modeled using a semicoupled, two-phase approach. Following a thermal calculation, the deformation of the mushy solid is computed using a compressive rheological model that neglects the pressure of the intergranular liquid. The nonzero expansion/compression of the solid and the solidification shrinkage are then introduced as source terms for the calculation of the pressure drop and pore formation in the liquid phase. A comparison between the simulation results and experimental data permits a detailed understanding of the specific conditions under which hot tears form under given conditions. It is shown that the failure modes can be quite different for these two experiments and that, as a consequence, the appropriate hot tearing criterion may differ. It is foreseen that a fully predictive theoretical tool could be obtained by coupling such a model with a granular approach. These two techniques do, indeed, permit coverage of the range of the length scales and the physical phenomena involved in hot tearing.

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Notes

  1. CalcoSOFT 3D is a trademark of ESI-Group, Paris, France.

  2. Abaqus is a trademark of Abaqus Inc., Pawtucket, RI.

  3. ProCAST is a trademark of ESI-GROUP, Paris, France.

  4. Intel Xeon is a trademark of Intel Corporation, Santa Clara, CA.

  5. Intel Itanium is a trademark of Intel Corporation, Santa Clara, CA.

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Acknowledgments

This work was carried out as part of the POST project. The authors acknowledge the Commission for Technology and Innovation (CTI, Grant No. 6167.1) and the industrial partners (Alcan (Switzerland and France)), HydroAluminium (Germany), Umicore (Brussels, Belgium), and General Motors (Detroit, MI) are acknowledged for their financial support. Finally, the authors thank Drs. G. Couturier, J.-M. Drezet, and O. Ludwig for their help with the porosity module and mechanical models; the authors also thank J.-L. Desbiolles for his assistance with aspects of the software.

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Authors and Affiliations

  1. Ecole Polytechnique Fédérale de Lausanne, CH-1015, Lausanne, Switzerland

    V. Mathier (Software Developer, Calcom-ESI SA, Parc Scientifique) & M. Rappaz (Professor, Computational Materials Laboratory, Institute of Materials Science, School of Engineering)

  2. Alcan CRV, FR-38341, Voreppe, France

    S. Vernède & P. Jarry (Ingénieurs expert de recherché)

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  1. V. Mathier
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  2. S. Vernède
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  3. P. Jarry
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  4. M. Rappaz
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Correspondence to V. Mathier.

Additional information

Manuscript submitted July 22, 2008.

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Mathier, V., Vernède, S., Jarry, P. et al. Two-Phase Modeling of Hot Tearing in Aluminum Alloys: Applications of a Semicoupled Method. Metall Mater Trans A 40, 943–957 (2009). https://doi.org/10.1007/s11661-008-9772-2

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