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Integrated Computational Materials Engineering (ICME) for Metals: Using Multiscale Modeling to Invigorate Engineering Design with Science by Mark F. Horstemeyer

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7.9 PREDICTIVE MODELING OF STRUCTURAL COMPONENTS FOR THE CASE STUDY OF THE CAST A356 ALUMINUM ALLOY

Now that the macroscale continuum ISV model has included the different length scale microstructural features into the pertinent ISV equations, and it has been calibrated and validated, it is now ready for predictive simulations. This means that since it is a physically based model, it can be used to predict ahead of time what could happen to a structural component given a particular boundary condition. However, one tactic to use is to look for a different complex structural problem to solve to help assure you of the model’s applicability. For the case study of the control arm here, there indeed was such a case. It included a cast A356 transportation carrier for a weapon.

7.9.1 Weapons Carrier Analysis

In this numerical–experimental study, a transportation carrier that used to transport U.S. Department of Energy (DOE) weapons was simulated to levels that exceeded the design load. This loading environment was similar to certain impacts on automotive parts in a crash. Cast A356 aluminum has been used in a U.S. DOE weapon transportation carrier as a load-bearing structure subjected to shipping environments. Cracks were observed in some carrier brackets when two weapons were stacked. Optical microscopy of the cast material in several regions of the transportation carrier was performed. The porosity was uniformly distributed among the eutectic region in the interdendritic boundaries. The ...

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