Numerical Determination of Initiation Fracture Toughness of High-Pressure Die Cast Aluminium Metal Matrix Composite Mate

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ORIGINAL ARTICLE

Numerical Determination of Initiation Fracture Toughness of High-Pressure Die Cast Aluminium Metal Matrix Composite Material Using FEM Analysis Chitragupt Swaroop Chitransh1 • Sanjeev Saxena2

Received: 8 June 2020 / Accepted: 7 October 2020 Ó The Indian Institute of Metals - IIM 2020

Abstract The critical stress intensity factor for highpressure die casted aluminium metal matrix composite material is rarely reported in the literature. The understanding of this parameter is very much essential for exploring the application of this material in automobile and aviation industries relying on light-weight materials. In the present study, critical stress intensity factor for pressure die cast aluminium alloy (ADC12) has been determined numerically, which compares well with experimental values. The variation due to fracture specimen thickness and relative crack size is also studied for the material. Keywords High-pressure die casting  Aluminium metal matrix composite  Finite element analysis  Fracture mechanics  Initiation fracture toughness List of Symbols g Nita plastic zone factor t Poison’s ratio rys Yield strength of material ALD Curve Area under load displacement curve of compact tension specimen ASTM American society of testing and materials CT Compact tension specimen E Modulus of elasticity Ecritical Critical energy corresponding to fracture & Sanjeev Saxena [email protected] 1

AcSIR, Advanced Materials and Processes Research Institute, Hoshangabad Road, Bhopal 462026, India

2

CSIR-Advanced Materials and Processes Research Institute, Hoshangabad Road, Bhopal 462026, India

FEM HPDC J Jc K Kc LLD MMC PN PS SIF SiC 3D a/W ADC B W W-a

Finite element analysis High-pressure die casting Contour path J-integral value Critical fracture toughness Stress intensity factor Critical stress intensity factor Load line displacement Metal matrix composite Plane strain Plane stress Stress intensity factor Silicon carbide particles Three-dimensional Relative crack size Aluminium die casting Thickness of compact tension specimen Width of compact tension specimen Width of un-cracked ligament

1 Introduction Over the last two to three decades of research works show the possibility of wide application of aluminium metal matrix composite (MMC) material in automobile components and in aerospace industry due to its properties like high specific stiffness, high specific strength, light-weight, higher thermal conductivity, low coefficient of thermal expansion, wear resistance, resistance to cracking, and fatigue resistance [1]. Other than these properties, such applications also require sufficient fracture toughness property in aluminium metal matrix composite material, wherein the development of simpler method for its

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evaluation is essential. In MMCs, a higher toughness property requires not only control over its constituents but also on the method of synthesis such as liquid (gravity casting or by high-pressure die casting (HPDC), etc.) or by powder metallurgy route. The variation o