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An integrated two-dimensional modeling method for predicting ductility of thin-walled die cast magnesium

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Abstract

In this paper, a two-dimensional (2D) microstructure-based modeling method is developed in order to predict the ductility of a thin-walled high pressure die cast magnesium (Mg) by considering the three-dimensional (3D) thru-thickness pore distributions. For this purpose, a series of 3D synthetic microstructure-based finite element models and the corresponding 2D models are first generated with various pore volume fractions, pore size distributions and pore shapes. The input material properties for the 2D models are determined based on the 3D cubic model with a spherical pore and the generalized Neuber’s rule. Based on the resulting ductility of the 3D and 2D models, a 3D/2D ductility correlation curve is developed as a function of the characteristics/shape of the input fracture strain curve used in the 3D model. The validity of the ductility correlation curve is examined with casting samples with actual microstructures. The results show that the suggested 2D modeling methodology can be used together with the ductility correlation curve in predicting the ductility of thin-walled Mg castings.

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Acknowledgements

Pacific Northwest National Laboratory is operated by Battelle Memorial Institute for the US Department of Energy under Contract No. DEAC05- 76RL01830. Oak Ridge National Laboratory is operated by UT-Battelle, LLC, for the U.S. Department of Energy under contract DE-AC05-00OR22725. This work was funded by the Department of Energy Office of FreedomCar and Vehicle Technologies under the Automotive Lightweighting Materials Program managed by Mrs. Sarah Kleinbaum.

Disclaimer This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof.

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Authors and Affiliations

  1. Pacific Northwest National Laboratory, Richland, WA, 99352, USA

    Kyoo Sil Choi & Erin I. Barker

  2. Oak Ridge National Laboratory, Oak Ridge, TN, 37830, USA

    Xin Sun

  3. Purdue University, West Lafayette, IN, 47907, USA

    Jie Song

  4. Tsinghua University, Beijing, People’s Republic of China

    Shou-Mei Xiong

  5. Ford Motor Company, Dearborn, MI, 48124, USA

    Joy Forsmark & Mei Li

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  1. Kyoo Sil Choi
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  2. Erin I. Barker
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  6. Joy Forsmark
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Correspondence to Xin Sun.

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Choi, K.S., Barker, E.I., Sun, X. et al. An integrated two-dimensional modeling method for predicting ductility of thin-walled die cast magnesium. Int J Fract 219, 203–220 (2019). https://doi.org/10.1007/s10704-019-00390-w

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  • DOI: https://doi.org/10.1007/s10704-019-00390-w

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