Progress and Challenges in Fracture Prediction of Die-Cast Lightweight Alloys

Kaiyue Liu

doi:10.62051/ijmsts.v4n3.02

Authors

Kaiyue Liu

DOI:

https://doi.org/10.62051/ijmsts.v4n3.02

Keywords:

Die-cast alloys, Fracture failure, Failure prediction, GISSMO, Mohr-Coulomb (MMC), Tension-compression asymmetry, Finite element analysis

Abstract

Die-cast alloys, such as aluminum, zinc, and magnesium alloys, are widely used in automotive, aerospace, and consumer electronics applications due to their excellent mechanical properties, castability, and cost-effectiveness. Fracture failure, however, remains a critical concern, directly affecting performance and service life. This review summarizes current advances in fracture prediction for die-cast alloys, including common alloy types, fracture mechanisms, failure modes, influencing factors, and predictive models. Key studies are cited to highlight the coupled effects of microstructural defects, stress state, and temperature on fracture behavior, and the applicability and limitations of models such as GISSMO and MMC are discussed. Future research directions are also outlined.

References

[1] Zhang, J., Zhong, G., Zou, C. et al. (2018). Research progress on high-vacuum die-cast aluminum alloys. Materials Review, 32(19), 375–378.

[2] Wang, Y., Li, J., Zhang, X. et al. (2021). Micromechanism of ductile fracture in die-cast A380 aluminum alloys under tensile loading. Materials Science and Engineering A, 817, 141347.

[3] Zhang, Q., Liu, H., Wang, Y. et al. (2020). In-situ XCT investigation on the fatigue crack initiation mechanisms in die-cast Al-Si-Cu alloys. Acta Materialia, 196, 143–156.

[4] Miyazaki, K. et al. (2019). Effect of $beta$-phase morphology on the room temperature ductility of die-cast AZ91D magnesium alloy. Journal of Magnesium and Alloys, 7(1), 104-112.

[5] Shabani, M. M., Miresmaeili, R. (2018). The effect of porosity on the fatigue behavior of die-cast A380 aluminum alloys. Materials & Design, 141, 351-360.

[6] Bao, Y., Wierzbicki, T. (2004). On fracture locus in the equivalent strain and stress triaxiality space. International Journal of Mechanical Sciences, 46(1), 81-98.

[7] Liang, W. et al. (2021). A new ductile fracture criterion for die-cast AM60 magnesium alloy considering the effect of stress triaxiality and Lode parameter. International Journal of Plasticity, 138, 102941.

[8] Yang, S., Li, X., Zhao, P. et al. (2019). Study on the intrinsic mechanical behavior of A356-T6 aluminum alloy under quasi-static uniaxial loading (Tension and Compression). Materials Science and Engineering A, 758, 46–58.

[9] Hu, X. (2019). High-temperature mechanical properties and creep behavior of die-cast A380 aluminum alloy. Journal of Materials Engineering and Performance, 28(5), 2730-2738.

[10] Gomez, C. et al. (2017). Ductile-to-brittle transition behavior of Zamak 3 die-casting alloy. Materials Characterization, 130, 150-157.

[11] Gurson, A. L. (1977). Continuum theory of ductile rupture by void nucleation and growth: Part I... Journal of Engineering Materials and Technology, 99(1), 2-15.

[12] Tvergaard, V., Needleman, A. (1984). Analysis of the cup-cone fracture in a round tensile bar. Acta Metallurgica, 32(1), 157-169.

[13] Han, Y. et al. (2020). Numerical simulation of ductile fracture in porous A380 aluminum alloy using the GTN damage model. Fatigue & Fracture of Engineering Materials & Structures, 43(8), 1729-1742.

[14] Johnson, G. R., Cook, W. H. (1985). Fracture characteristics of three metals subjected to various strains, strain rates, temperatures and pressures. Engineering Fracture Mechanics, 21(1), 31-48.

[15] Ge, Y., Dong, L., Song, H., Gao, L., Xiao, R. (2022). On the prediction of material fracture for thin-walled cast alloys using GISSMO. Metals, 12(11), 1850.

[16] Zhang, S., Wu, X., Yang, M., Ren, P., Meng, X. (2023). Simulation of fracture performance of die-cast A356 aluminum alloy based on modified Mohr–Coulomb model. Applied Sciences, 13(11), 6456.

[17] Lee, J., Kim, S-J., Park, H., Bong, H. J., Kim, D. (2018). Metal plasticity and ductile fracture modeling for cast aluminum alloy parts. Journal of Materials Processing Technology, 255, 584-595.

[18] Xiao, Y., Hu, Y. (2019). An extended iterative identification method for the GISSMO model. Metals, 9(5), 568.

[19] Zhao, H. et al. (2022). X-ray tomography-based micro-FE modeling of damage evolution in die-cast aluminum alloys. Acta Materialia, 226, 117621.

[20] Yang, B., Song, H., Wang, S., Chen, S., Zhang, S. (2021). Tension-compression mechanical behavior and corresponding microstructure evolution of cast A356-T6 aluminum alloy. Materials Science & Engineering A, 821, 141613.