5th International Conference on Advances in Solidification Processes (ICASP-5) 5th International Symposium on Cutting Edge of Computer Simulation of Solidification, Casting and Refining (CSSCR-5)

The need for efficient and clean solutions, due to the increasing current environmental regulations puts extra pressure on new combustion engine development, to compete in a market with alternative driving concepts. Downsizing and weight reduction can reduce the engine emission and efficiency, but require light alloys with superior thermo-mechanical properties for high temperature exposure to maintain the same engine performance. Cast Al-Cu could be alternative to standard Al- Si alloys for new engine generations due to their higher temperature strength, creep-resistance and long term stability of engine components. In Al-Si and Al-Cu cast alloys with heterogeneous microstructures a composite-like deformation behavior is responsible for superior high temperature properties. Stiff Si or Al2Cu particles, respectively reinforce a ductile -Al matrix to a composite with improved thermo-mechanical strength. However, different Young’s moduli and coefficients of thermal expansion are responsible for micro stress gradients and unpredictable micro crack formation under operation. These micro-mechanical deformation mechanisms in Al-Si and Al-Cu systems, responsible for crack initiation and growth, have been scarcely investigated so far. This manuscript describes an example of elasto-plastic deformation mechanisms in an AlCu7 alloy. Tensile testing shows anomalous macroscopic deformation behavior indicating unknown internal micro-mechanical processes. External loading until yield strength and beyond are applied under laboratory conditions and during in-situ neutron diffraction. The results of macroscopic deformation and micro strain evolution are compared and correlated with the heterogeneous micro structure. High resolution synchrotron computed tomography reveals conclusions on the micro-mechanic deformation mechanisms and their effects on the macroscopic damage initiation and material’s service performance.