ORALS

Predicting location-specific microstructure and properties of industrial castings is a critical part of the Integrated Computational Materials Engineering (ICME) framework for lightweight casting design and manufacturing. This talk will present an overview on several models/methods developed at The Ohio State University (in collaboration with industrial partners) for the ICME framework. The talk will include a) three-dimensional grain structure model coupling process modeling and cellular automaton techniques [1]; b) microporosity model including both gas (hydrogen) and shrinkage effects [2, 3]; c) oxide-related defect prediction based on a new Oxide Entrainment Number (OEN) model [4]; and d) a new design methodology [5] linking location-specific microstructure (including defects) to location-specific mechanical properties of an aluminum casting. The modeling results on a simple wedge casting of a ternary aluminum alloy have been validated by X-ray Micro Computed Tomography experiments and mechanical testing. This new ICME framework proves to be a critical tool for efficient and effective casting design based on location-specific properties.

References:
1. C. Gu, Y. Lu, E. Cinkilic, J. Miao, A.D. Klarner, X. Yan, A.A. Luo, “Predicting grain structure in high pressure die casting of aluminum alloys: A coupled cellular automaton and process model”, Computational Materials Science, 2019, 161, 64-75.
2. C. Gu, Y. Lu, C.D. Ridgeway, E. Cinkilic, J. Miao, A.A. Luo, “Three-dimensional cellular automaton simulation of coupled hydrogen porosity and microstructure during solidification of ternary aluminum alloys”, Scientific Reports, 2019, 9, (1), 1-12, https://doi.org/10.1038/s41<span class="fon_main_wrapper"><span phone-source="598-019-49531" class="fon-phone-wrap fon-hightlighted active-call" id="fon-phone-QDnLiSvG61">598-019-49531</span><a phone-source="598-019-49531" href="#" class="fonCallLinkButton active-call"><img src="data:image/png;base64,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" alt="F"/></a></span>-0.
3. C. Gu, C.D. Ridgeway, E. Cinkilic, Y. Lu, A.A. Luo, “Predicting Gas and Shrinkage Porosity in Solidification Microstructure: A coupled Three-dimensional Cellular Automaton Model”, Journal of Materials Science and Technology, 2020, 49, 91-105, https://doi.org/10.1016/j.jmst.2020.02.028.
4. C.D. Ridgeway, K. Ripplinger, D. Detwiler, M. A.A Luo, “A New Model for Predicting Oxide-related Defects in Aluminum Castings”, Metallurgical and Materials Transactions B, 2020, in press.
5. C.D. Ridgeway, C. Gu, K. Ripplinger, D. Detwiler, M. Ji, S. Sohgrati, A.A Luo, “Prediction of location specific mechanical properties of aluminum casting using a new CA-FEA (cellular automaton-finite element analysis) approach”, Materials and Design, 2020, 108929, https://doi.org/10.1016/j.matdes.2020.108929.