ECCOMAS 2024

Modeling of Cyclic Deformation in a Secondary Cast-Aluminum Alloy: a Crystal Plasticity Approach

  • Prabhu, Nikhil (KU Leuven)
  • Eisenlohr, Philip (Michigan State University)
  • Diehl, Martin (KU Leuven)

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Repeated recycling of aluminum is economically and environmentally advantageous but faces numerous challenges. An important one of them is trace content of Iron (Fe), which enters into the cycle through improper sorting of metal scrap and from unprotected steel tools and/or from furnace equipment, used in the recycling process. Because of its low solid solubility in Aluminum, Fe forms intermetallic phases that prove to be detrimental to the mechanical performance of secondary cast aluminum alloys. The Fe-rich intermetallic phases not only act as potential crack nucleation and/or propagation sites but also promote porosity formation by obstructing the flow of the melt. Therefore, it becomes imperative to study the ill effects inflicted by the intermetallic compounds on mechanical performance of secondary cast-Aluminum alloys. The present work focuses on development of statistically-equivalent 3D microstructures of secondary aluminum alloy and investigation of its mechanical performance under cyclic loading through crystal plasticity simulations. In particular, a slip system-level cyclic hardening model incorporated in an FFT-based spectral solver is employed to simulate cyclic deformation of the generated microstructures. Suitable damage indicators are employed to interpret the results and a detailed investigation of the impact of intermetallic phases on alloy performance is carried out.