Study of 3D Pores and Its Relationship with Crack Initiation Factors of Aluminum Alloy Die Castings

Observing different types of pores in aluminum alloy from A356 high-pressure die casting by X-ray computerized tomography and scanning electron microscopy, we found that equivalent spherical diameters of pores obeyed the 3-parameter lognormal distribution rather than the 2-parameter one. Statistically, the sphericity of most round gas pores with smooth inner surfaces consisting of oxide films was > 0.58, while the sphericity of shrinkage pores with unfractured dendrites was < 0.40. Sphericity range for the gas-shrinkage pores, composed of gas pores and shrinkage pores with long tails, was 0.40-0.58. Finite element analysis with simulation of the Von Mises stress distribution around the actual 3D pores among crack generation was performed. Tensile test simulation showed that cracks often originated from the shrinkage pores and the gas-shrinkage pores, rather than from the gas pores. This method also can be used to predict fracture strength of samples with pores. For our samples, results obtained using this method showed that simulated fracture strength was slightly higher than experimentally determined strength.