Effects of Dwell Time on the Deformation and Fatigue Behaviour of A356-T7 Cast Aluminium Alloys Used in High Specific Power IC Engine Cylinder Heads
Abstract
:1. Introduction
2. Materials and Methods
2.1. Material
2.2. Testing
2.2.1. Test Plan and Sample Preparation
2.2.2. Test Equipment
3. Results
3.1. Effect of Hold Time on Stress Evolution
3.2. Effect of Strain Amplitude during Hold Time on Stress Relaxation
- With the material exhibiting insignificant hardening with increasing plasticity at elevated temperatures, the stress relaxation measured is identical for all the tested load levels at 250 °C, in contrast to the lower temperatures, where the material exhibits considerable hardening with increasing plasticity.
- As mentioned above, part of the explanation could be that the relaxation at the highest temperature (250 °C) is rapid enough to complete already during the compressive straining.
3.3. Stress Relaxation during Multiple Hold Time Events
3.4. Effect of Dwell Time on Peak and Trough Stress Evolution
3.5. Effect of Hold Times at Room Temperature
4. Discussion of the Experimental Results
4.1. General
4.2. Stress Relaxation during the Hold Time
4.2.1. Stress Relaxation at Elevated Temperatures
4.2.2. Stress Relaxation at Room Temperature
4.3. Effect of Hold Time on Number of Cycles to Failure
5. Numerical Modelling
5.1. Calibration Procedure and Results
5.2. Verification of the Model
5.3. Analysis of the Modelling Results and Limitations of the Model
6. Conclusions
- The material exhibits a significant stress relaxation at all temperatures and load levels with a rapidly decreasing stress relaxation rate.
- The magnitude of stress relaxation is influenced significantly by the load level. This effect is stronger at the lower test temperatures of 150 °C than at the higher test temperature of 250 °C. This can be attributed to the plastic hardening behaviour of the alloy at lower temperatures, while the material owing to excessive stress relaxation shows insignificant hardening at 250 °C.
- The dwell times at constant compressive strains have no discernible influence on the cyclic hardening behaviour or the fatigue life of the material, even at elevated temperatures.
- The visco-plastic deformation behaviour can be modelled with a high degree of accuracy using a combination of the Chaboche combined non-linear kinematic and isotropic mixed hardening model and the rate-dependent Cowper–Symonds overstress power law model.
- Further research using TMF testing is strongly recommended along the lines of the work by Beck et al. [19]. A detailed study of the combined effect of stress relaxation associated with the low frequency thermal start–stop cycle and superimposed high frequency loads associated with the combustion cycles is needed to get a more complete picture of the effect of these loads on the durability of cylinder heads.
Author Contributions
Funding
Conflicts of Interest
References
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Si | Cu | Mg | Ti | Fe | Mn | B | Others | Al |
---|---|---|---|---|---|---|---|---|
6.8 | 0.53 | 0.35 | 0.12 | 0.10 | 0.07 | 0.0012 | <0.05 | Bal |
Test Series | Test Temperatures | Load Levels | Replicas |
---|---|---|---|
Series A: Strain controlled tests with a hold time of 600 s | 150, 200, and 250 °C | Total Strain Amplitudes εTotAmp: 0.2%, 0.3%, and 0.4% Strain Ratio: Rε = −1 | 2 at each load-temperature combination |
Series B: Strain controlled tests with a hold time of 3600 s | RT, 150, 200, and 250 °C | Total Strain Amplitude εTotAmp: 0.4% Strain Ratio: Rε = −1 | 2 at each temperature |
Extensometer | Temperature |
---|---|
Instron 2620-603 axial clip-on dynamic extensometer (Instron, Norwood, MA, USA) | RT & 150 °C |
Epsilon 3555-010M-020 high temperature 146 axial capacitive extensometer (Epsilon Technology Corporation, Jackson, WY, USA). | 200 & 250 °C |
Temperature °C | Young’s Modulus [GPa] | Yield [Mpa] | Kinematic Hardening Parameter [Mpa] | [-] | Kinematic Hardening Parameter [MPa] | [-] | [MPa] | Hardening Parameter [-] | Multiplier [-] | Exponent [-] |
---|---|---|---|---|---|---|---|---|---|---|
RT | 69.85 | 90.00 | 156,178 | 3266 | 41,437 | 0 | 17 | 0.6141 | 0.0179 | 1.4422 |
150 | 69.55 | 64.65 | 154,190 | 2519 | 22,216 | 0 | −1.5 | 0.4601 | 0.0118 | 3.8595 |
200 | 66.33 | 54.50 | 115,350 | 1869 | 7286 | 0 | −10 | 0.6161 | 0.0062 | 6.9943 |
250 | 60.97 | 41.79 | 80,620 | 2161 | 3492 | 0 | −40 | 0.0315 | 0.0018 | 6.9943 |
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Natesan, E.; Meyer, K.A.; Eriksson, S.; Ahlström, J.; Persson, C. Effects of Dwell Time on the Deformation and Fatigue Behaviour of A356-T7 Cast Aluminium Alloys Used in High Specific Power IC Engine Cylinder Heads. Materials 2020, 13, 2727. https://doi.org/10.3390/ma13122727
Natesan E, Meyer KA, Eriksson S, Ahlström J, Persson C. Effects of Dwell Time on the Deformation and Fatigue Behaviour of A356-T7 Cast Aluminium Alloys Used in High Specific Power IC Engine Cylinder Heads. Materials. 2020; 13(12):2727. https://doi.org/10.3390/ma13122727
Chicago/Turabian StyleNatesan, Elanghovan, Knut Andreas Meyer, Stefan Eriksson, Johan Ahlström, and Christer Persson. 2020. "Effects of Dwell Time on the Deformation and Fatigue Behaviour of A356-T7 Cast Aluminium Alloys Used in High Specific Power IC Engine Cylinder Heads" Materials 13, no. 12: 2727. https://doi.org/10.3390/ma13122727