SpringerLink
Log in

As-Cast Residual Stresses in an Aluminum Alloy AA6063 Billet: Neutron Diffraction Measurements and Finite Element Modeling

  • Published:
Metallurgical and Materials Transactions A Aims and scope Submit manuscript

Abstract

The presence of thermally induced residual stresses, created during the industrial direct chill (DC) casting process of aluminum alloys, can cause both significant safety concerns and the formation of defects during downstream processing. Although numerical models have been previously developed to compute these residual stresses, most of the computations have been validated only against measured surface distortions. Recently, the variation in residual elastic strains in the steady-state regime of casting has been measured as a function of radial position using neutron diffraction (ND) in an AA6063 grain-refined cylindrical billet. In the present study, these measurements are used to show that a well-designed thermomechanical finite element (FE) process model can reproduce relatively well the experimental results. A sensitivity analysis is then carried out to determine the relative effect of the various mechanical parameters when computing the as-cast residual stresses in a cylindrical billet. Two model parameters have been investigated: the temperature when the alloy starts to thermally contract and the plasticity behavior. It is shown that the mechanical properties at low temperatures have a much larger influence on the residual stresses than those at high temperatures.

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

Access this article

Log in via an institution

Subscribe and save

Springer+ Basic
EUR 32.99 /Month
  • Get 10 units per month
  • Download Article/Chapter or Ebook
  • 1 Unit = 1 Article or 1 Chapter
  • Cancel anytime
Subscribe now

Buy Now

Price includes VAT (Germany)

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12

Similar content being viewed by others

Notes

  1. ABAQUS is a trademark of Dassault Systems Inc., Providence, RI.

References

  1. J.-M. Drezet: Ph.D. Thesis no. 1509, dir. M. Rappaz, Ecole Polytechnique Federale de Lausanne, Lausanne, 1996, http://library.epfl.ch/theses/?display=detail&nr=1509.

  2. J.-M. Drezet and M. Rappaz: Metall. Mater. Trans. A, 1996, vol. 27A, pp. 3214–25.

    Article  CAS  ADS  Google Scholar 

  3. B. Hannart, F. Cialti, and R. Schalkwijk: Light Metals, A.T. Taberaux, ed., San Francisco, CA, 1994, TMS, Warrendale, PA, 1994, pp. 879–87.

  4. H.G. Fjaer and A. Mo: Metall. Mater. Trans. B, 1990, vol. 21B, pp. 1049–61.

    CAS  ADS  Google Scholar 

  5. J. Sengupta, S.L. Cockcroft, D.M. Maijer, and A. Larouche: Mater. Sci. Eng. A, 2005, vol. 397, pp. 157–77.

    Article  Google Scholar 

  6. W. Boender, A. Burghardt, E.P. Van Klaveren, and J. Rabenberg: Light Metals, A.T. Taberaux, ed., Charlotte, NC, 2004, TMS, Warrendale, PA, 2004, pp. 679–84.

  7. O. Ludwig, J.-M. Drezet, B. Commet, and B. Heinrich: Model Casting, Welding and Advanced Solidification Processing XI, C.A. Gandin and M. Bellet, eds., Nice, France, 2006, TMS, Warrendale, PA, 2006, pp. 185–92.

  8. W. Droste, J.-M. Drezet, G.-U. Grun, and W. Schneider: in Continuous Casting, K. Ehrke and W. Schneider, eds., Wiley-VCH, Frankfurt, 2000, pp. 175–83.

  9. W. Droste, G.-U. Grun, W. Schneider, and J.-M. Drezet: Light Metals, W. Schneider, ed., Seattle, WA, 2002, TMS, Warrendale, PA, 2002, pp. 703–08.

  10. A.B. Phillion, D. Maijer, and S.L. Cockcroft: Model Casting, Welding and Advanced Solidification Processing XI, C.A. Gandin and M. Bellet, eds., Opio, France, 2006, TMS, Warrendale, PA, pp. 807–14.

  11. K. Escobar, B.B. Gonzalez, J.L. Ortiz, P.N. Nguyen, D. Bowden, J. Foyos, J. Ogren, E.W. Lee, and O.S. Es-Said: Mater. Sci. Forum, 2002, vols. 396–402, pp. 1235–40.

    Article  Google Scholar 

  12. S. Ganguly, M.E. Fitzpatrick, and L. Edwards: Mater. Sci. Forum, 2005, vols. 790–791, pp. 223–28.

    Article  Google Scholar 

  13. J. Moriceau: in Light Metals, R. Rentsch, ed., TMS, Warrendale, PA, 1975, pp. 119–33.

  14. J.S. Robinson, C.E. Truman, S. Hossain, and R. Wimpory: Mater. Sci. Forum, 2008, vol. 571–572, pp. 113–18.

    Google Scholar 

  15. M.B. Prime: Appl. Mech. Rev., 1999, vol. 52, pp. 75–96.

    Article  Google Scholar 

  16. J. Lu: Handbook of Measurement of Residual Stresses, The Society for Experimental Mechanics Inc., The Fairmont Press, New York, NY, 1996.

  17. L. Bichler, C. Ravindran, and D. Sediako: Can. Met. Q., 2009, vol. 48, pp. 81–90.

    CAS  Google Scholar 

  18. H. Hao, D.M. Maijer, M.A. Wells, A.B. Phillion, and S.L. Cockcroft: Metall. Mater. Trans. A, 2010, vol. 41A, pp. 2067–77.

    Article  CAS  ADS  Google Scholar 

  19. J.-M. Drezet, A. Evans, C. Jaquerod, and A.B. Phillion: Jim Evans Honorary Symp., Seattle, WA, 2010, B. Li, B. Thomas, L. Zhang, F. Doyle, and A. Campbell, eds., TMS, Warrendale, PA, 2010, pp. 43–50.

  20. U. Stuhr: Nucl. Instrum. Methods Phys. Res. A, 2005, vol. 545, pp. 319–29.

    Article  CAS  ADS  Google Scholar 

  21. U. Stuhr, J. Spitzer, A. Egger, P. Hofer, P. Rasmussen, D. Graf, A. Bollhalder, M. MSchild, G. Bauer, and W. Wagner: Nucl. Instrum. Methods Phys. Res. A, 2005, vol. 545, pp. 330–38.

    Article  CAS  ADS  Google Scholar 

  22. J.-M. Drezet, M. Rappaz, G.U. Grun, and M. Gremaud: Metall. Mater. Trans. A, 2000, vol. 31A, pp. 1627–34.

    Article  CAS  Google Scholar 

  23. X. Doré, H. Combeau, and M. Rappaz: Acta Mater., 2000, vol. 48, pp. 3951–62.

    Article  Google Scholar 

  24. EMPACT: European Modelling Programme on Aluminium Casting Technology, European Union Research Project No. BE-1112, 1996–2000.

  25. J.-M. Drezet, B. Commet, H.G. Fjaer, and B. Magnin: Model Casting, Welding and Advanced Solidification Processing IX, Aachen, DM, 2000, P.R. Sahm, P.N. Hansen, and J.G. Conley, eds., TMS, Warrendale, PA, 2000, pp. 33–40.

  26. A.B. Phillion, S. Thompson, S.L. Cockcroft, and M.A. Wells: Mater. Sci. Eng. A, 2008, vol. 497, pp. 388–94.

    Article  Google Scholar 

  27. A. Strangeland, A. Mo, and D.G. Eskin: Metall. Mater. Trans. A, 2006, vol. 37A, pp. 2219–29.

    Article  Google Scholar 

  28. A.B. Phillion, S.L. Cockcroft, and P.D. Lee: Acta Mater., 2008, vol. 56, pp. 4328–38.

    Article  CAS  Google Scholar 

  29. B. Magnin, L. Maenner, L. Katgerman, and S. Engler: Mater. Sci. Forum, 1996, vols. 217–222, pp. 1209–14.

    Article  Google Scholar 

  30. W.M. van Haaften, B. Magnin, W.H. Kool, and L. Katgerman: Metall. Mater. Trans. A, 2002, vol. 33A, pp. 1971–80.

    Article  ADS  Google Scholar 

  31. J.-M. Drezet and M. Rappaz: Proc. 4th Eur. Conf. on Residual Stresses, S. Denis, ed., Société Francaise de Métallurgie et Matériaux, Cluny, France, 1996, pp. 357–66.

  32. F. Heymes, B. Commet, B. Dubost, P. Lassince, P. Lequen, and G.M. Reynaud: 1st Int. Non-Ferrous Processing and Technology Conf., St. Louis, MO, 1997, T. Bains, S. Mackenzie, and G.M. Davidson, eds., ASM INTERNATIONAL, Materials Park, OH, 1997, pp. 249–55.

  33. M. Lalpoor, D.G. Eskin, and L. Katgerman: Metall. Mater. Trans. A, 2009, vol. 40A, pp. 3304–13.

    Article  CAS  ADS  Google Scholar 

  34. D. Bru, J. Devaux, J.M. Bergheau, and D. Pont: Mathematical Modeling of Weld Phenomena 3, H. Cerjak, ed., The Institute of Metals, Graz, Austria, 1997, pp. 456–63.

  35. D. Dye, K.T. Conlon, and R.C. Reed: Metall. Mater. Trans. A, 2004, vol. 35A, pp. 1703–13.

    Article  CAS  ADS  Google Scholar 

Download references

Acknowledgments

The authors express their sincere thanks to C. Jaquerod, Alcan ATI (Valais, Switzerland), for providing the experimental AA6063 billet, and A. Evans, Swiss Spallation Neutron Source, Paul Scherrer Institut (Villigen, Switzerland) for his expertise and assistance with the ND measurements using the POLDI apparatus. One of the authors (AP) also acknowledges the Natural Sciences and Engineering Research Council of Canada for financial assistance.

Author information

Authors and Affiliations

  1. LSMX, Ecole Polytechnique Fédérale de Lausanne, Station 12, CH-1015, Lausanne, Switzerland

    J.-M. Drezet (Senior Scientist)

  2. School of Engineering, University of British Columbia, Kelowna, BC, V1V 1V7, Canada

    A. B. Phillion (Assistant Professor)

Authors
  1. J.-M. Drezet
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. A. B. Phillion
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to J.-M. Drezet.

Additional information

Manuscript submitted June 8, 2010.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Drezet, JM., Phillion, A.B. As-Cast Residual Stresses in an Aluminum Alloy AA6063 Billet: Neutron Diffraction Measurements and Finite Element Modeling. Metall Mater Trans A 41, 3396–3404 (2010). https://doi.org/10.1007/s11661-010-0424-y

Download citation

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11661-010-0424-y

Keywords

Search

Navigation