In several studies of the magnesium alloys AM50 and AM60, elongation at failure or ductility has been reported to correlate with fracture toughness in Mg alloys. However, HPDC Mg alloys do have a lower ductility (elongation at failure) than more commonly used wrought steel or aluminum components. Thus, most magnesium components are produced by high-pressure die casting (HPDC). This enables part consolidation and potential cost savings. Additionally, the excellent high-pressure die castability of many Mg alloys allows for more complex and one-piece designs compared to traditional steel stampings and even some Al castings. The low density and favorable stiffness-to-weight ratio of Mg alloys enable considerable weight savings on components. 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.Īs the need for weight savings and fuel economy has increased, so has the interest in using magnesium alloys for a wider variety of automotive applications.
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. Local properties were predicted, and the local property (quality map) model was compared with a prototype production component. Casting simulations were also conducted for each experimental condition.
Over 1,200 tensile samples were excised from cast parts and tested. A design of experiment (DOE) was created to examine the role of various casting parameters on local properties such as ductility and yield strength. 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. 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.
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