Improved prediction of low-cycle fatigue life for high-pressure die-cast aluminium alloy AlSi9Cu3 with significant porosity

The fatigue life of a high-pressure die-cast alloy, AlSi9Cu3, with significant porosity is investigated. Standard specimens were cyclically loaded (R = -1) until fatigue rupture occurred. The specimens were mu-CT scanned to obtain a 3D representation of the pores. Models were used to computationally predict the fatigue life using two different methods. First, the fatigue life was predicted using a notch-strain approach combined with a Coffin-Manson durability relationship for homogeneous material. Second, the fatigue life was predicted using an homogenised un-notched model that was combined with an adapted Coffin-Manson relationship which considered a fatigue life reduction due to different pore effects.

Automated summary

The study investigated the fatigue life of a high-pressure die-cast alloy with significant porosity, AlSi9Cu3. Results showed that pores have a significant influence on fatigue life, and two different methods were used to predict the fatigue life.