Alan A. Luo

Abstract:

Predicting location-specific microstructure and properties of industrial castings is a critical part of the Integrated Computational Materials Engineering (ICME) framework for lightweight casting design and manufacturing. This talk will present an overview on several models/methods developed at The Ohio State University (in collaboration with industrial partners) for the ICME framework. The talk will include a) three-dimensional grain structure model coupling process modeling and cellular automaton techniques [1]; b) microporosity model including both gas (hydrogen) and shrinkage effects [2, 3]; c) oxide-related defect prediction based on a new Oxide Entrainment Number (OEN) model [4]; and d) a new design methodology [5] linking location-specific microstructure (including defects) to location-specific mechanical properties of an aluminum casting. The modeling results on a simple wedge casting of a ternary aluminum alloy have been validated by X-ray Micro Computed Tomography experiments and mechanical testing. This new ICME framework proves to be a critical tool for efficient and effective casting design based on location-specific properties.