Methods of predicting residual stresses and distortion in quenched aluminum castings

Abstract

Computational systems, methods, and articles of manufacture to predict at least one of residual stresses and distortion in quenched aluminum castings. Residual stresses and distortion may be predicted through incorporating thermal strains induced during quenching with the nonlinear constitutive behavior of quenched microstructures of a quenched aluminum casting, wherein thermal strains arise generally from non-uniform transient temperature distribution of the casting during quenching. The transient temperature distribution of the aluminum casting during quenching may be calculated based on heat transfer coefficients specific to one or more nodes, elements and/or zones on the surfaces of the aluminum casting. The nonlinear constitutive behavior of the quenched aluminum casting may be modeled as functions of temperatures, strain rates, and microstructure variations. A material constitutive model accounts for not only strain hardening and creep, but also precipitate hardening. Thereby, residual stresses and distortion in the quenched aluminum castings can be predicted using the embodiments.

Description

Technical field [0001] The present invention generally relates to residual stresses and deformations induced in aluminum alloys, including aluminum alloy castings, during the quenching / cooling process. More specifically, the present invention relates to a system, method, and manufactured article for predicting residual stress and deformation in a quenched aluminum casting after solution treatment. Background technique [0002] Residual stress is usually defined as the residual stress in the product / part / object after the manufacturing process. Residual stresses may exist in engineering castings, films, surface coatings, composites and multiphase materials. Residual stress can arise from many sources. For example, macroscopic residual stress can be generated from heat treatment, machining, secondary thermal and mechanical processes, and assembly procedures, while microstructure residual stress is usually caused by thermal expansion / contraction mismatch between phases and componen...

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Problems solved by technology

Also, it is often impractical to measure residual stresses in every location of a part, not only because of geometric constraints, but also because of the time and expense required to do so

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