Study of the Influence of Silicon Phase Morphology on the Microstructural Stress Distribution in Al–Si Alloys Using Object Oriented Finite Element Modeling

Authors

  • Nadimpalli Raghukiran,

    1. Materials Processing Section, Department of Metallurgical and Materials Engineering, Indian Institute of Technology Madras (IIT Madras), Chennai, India
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  • Aslam Kunhi Mohamed,

    Current affiliation:
    1. Section of Materials Science and Engineering, Swiss Federal Institute of Technology (EPFL), Lausanne, Switzerland
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  • Ravi Kumar

    Corresponding author
    1. Materials Processing Section, Department of Metallurgical and Materials Engineering, Indian Institute of Technology Madras (IIT Madras), Chennai, India
    • Materials Processing Section, Department of Metallurgical and Materials Engineering, Indian Institute of Technology Madras (IIT Madras), Chennai600036India

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  • Authors acknowledge the efforts of Centre for Theoretical and Computational Materials Science (CTCMS), National Institute of Standards and Technology (NIST) Gaithersburg, USA in developing the OOF2 code.

Abstract

Near-eutectic Al–Si alloys were produced by conventional casting and spray forming resulting in microstructural differences due to process dependent cooling rates. The as-sprayed alloy exhibited fine equiaxed Si particles uniformly distributed throughout the matrix in contrast to the as-cast alloy, which exhibited acicular morphology with relatively large needle-like Si particles. The effect of Si morphology on the microstructural stress distribution of the as-cast and as-sprayed alloys was estimated by simulating uni-axial tensile loads on microstructures using Object Oriented Finite Element code (OOF2). Microstructures of the as-sprayed alloy experienced relatively low and uniform stress distribution, while the microstructural stress distribution in the as-cast alloy was significantly influenced by the orientation of the needle shaped silicon particles.

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