Use of simulation to predict microstructure and mechanical properties in an as-cast aluminium cylinder head comparison - with experiments

Abstract

This contribution aims to validate a newly developed addon module to a commercial simulation software, which enables the prediction of the microstructure and mechanical properties of aluminium cast alloys under different casting conditions. The simulation of the casting process and the resulting microstructure and mechanical properties, permits a reduction of experimental testing and providing the best solution of process and material selections, thereby making the design and development process more cost efficient. The simulation results are compared with the investigation of the microstructural and mechanical behaviours of an As-Cast Aluminium cylinder head processed by semi permanent gravity die casting. It is demonstrated that the predictions made by the simulations are comparable to the experimental results. In order to further enhance the quality of the simulation tool, it is of significance to gain more experience from comparisons with complex castings of different aluminium alloys, where the microstructure as well as the mechanical properties are carefully evaluated.