Microtomographic study and finite element analysis of the porosity harmfulness in a cast aluminium alloy

An accurate methodology based on microtomography, image analysis and finite element analysis (FEA) has been developed to investigate the causes of fatigue fracture in the pressure-cast aluminium alloy AlSi9Cu3 (Fe). Five samples have been tested. In each case, porosity was the primary cause for failure. This is evidenced by the initiation and propagation of cracks from individual pores. Volumetric images of the samples internal porosity at the...