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Microstructural Inclusion Influence on Fatigue of a Cast A356 Aluminum Alloy

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Abstract

We examine the dependence of fatigue properties on the different size scale microstructural inclusions of a cast A356 aluminum alloy in order to quantify the structure-property relations. Scanning electron microscopy (SEM) analysis was performed on fatigue specimens that included three different dendrite cell sizes (DCSs). Where past studies have focused upon DCSs or pore size effects on fatigue life, this study includes other metrics such as nearest neighbor distance (NND) of inclusions, inclusion distance to the free surface, and inclusion type (porosity or oxides). The present study is necessary to separate the effects of numerous microstructural inclusions that have a confounding effect on the fatigue life. The results clearly showed that the maximum pore size (MPS), NND of gas pores, and DCS all can influence the fatigue life. These conclusions are presumed to be typical of other cast alloys with similar second-phase constituents and inclusions. As such, the inclusion-property relations of this work were employed in a microstructure-based fatigue model operating on the crack incubation and MSC with good results.

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Acknowledgments

The authors recognize Richard Osborne and Don Penrod for their encouragement of this study, Gerry Shulke for producing the plates, and Westmoreland Mechanical Testing and Research for testing the specimens. This work has been sponsored by the United States Department of Energy, Sandia National Laboratories, under Contract No. DE-AC04-94AL85000, and the Center for Advanced Vehicular Systems (CAVS) at Mississippi State University.

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Authors and Affiliations

  1. Center for Advanced Vehicular Systems (CAVS), Mississippi State University, Mississippi State, MS, 39762, USA

    J.B. Jordon (Assistant Research Professor)

  2. Center for Advanced Vehicular Systems (CAVS) and Department of Mechanical Engineering, Mississippi State University, Mississippi State, MS, 39762, USA

    M.F. Horstemeyer (Professor)

  3. Sandia National Laboratories, Livermore, CA, 94551-0969, USA

    N. Yang (Materials Scientist)

  4. Arvida R&D Centre, Rio Tinto Alcan, Jonquiere, QC, G7S-4K8, Canada

    J.F. Major (Material Scientist)

  5. School of Materials Science and Engineering, Georgia Institute of Technology, Atlanta, GA, 30332, USA

    K.A. Gall (Professor)

  6. Department of Mechanical Engineering, Alfred University, Alfred, NY, 14802, USA

    J. Fan (Professor)

  7. George Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA, 30332, USA

    D.L. McDowell (Professor)

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  1. J.B. Jordon
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  2. M.F. Horstemeyer
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  3. N. Yang
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  4. J.F. Major
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  5. K.A. Gall
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  6. J. Fan
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  7. D.L. McDowell
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Corresponding author

Correspondence to J.B. Jordon.

Additional information

Manuscript submitted May 4, 2009.

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Jordon, J., Horstemeyer, M., Yang, N. et al. Microstructural Inclusion Influence on Fatigue of a Cast A356 Aluminum Alloy. Metall Mater Trans A 41, 356–363 (2010). https://doi.org/10.1007/s11661-009-0088-7

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  • DOI: https://doi.org/10.1007/s11661-009-0088-7

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