Quantitative evaluation of fatigue life of cast aluminium alloys by non-destructive testing and parameter model

The presence of production-related defects in cast aluminium alloy components leads to reduction in their fatigue strength. The optimal use of their high strength-to-weight benefits is thereby restricted. There is currently only qualitative approach relating the defects characteristics to fatigue analysis. This work presents a method to quantitatively evaluate the fatigue life of defect-prone cast aluminium alloys. The investigation is carried-out by non-destructive analysis of cast aluminium alloy samples using X-Ray computed tomography. The microstructure discontinuities are characterized and quantified in terms of defect size, morphology and distance to specimen surface. These are subsequently used as input in a new parameter model for fatigue life calculation. The results correlate with fatigue experiments and finite-element calculations. This approach provides the possibility to extensively evaluate the fatigue properties of cast aluminium alloy components based on non-destructive test methods. It guarantees an improvement of control mechanisms within the scope of quality assurance.