Caractérisation des variabilités Matériaux/ Process pour une convergence produit de fonderie par approche prédictive

Abstract : Secondary Al-Si alloys are widely used in automotive industry for engine blocks because they offer a considerable weight reduction whilst maintaining good mechanical properties. The ever-expanding internationalisation of production, with same stages of production processes spread across a number of countries to produce locally, causes however high variability in the casting products. The chemical composition of the same alloys and the working variables of the unchanged high-pressure die casting process (HPDC) may change for the same casting parts from one country to another, they can even sometimes vary from one manufacturing site to another within the same country. Designing for aluminium automotive components does call today for new deterministic design methods that are often achieved from European material and casting process databases, which can affect the properties of these parts in the case of a location outside Europe. Thus, it is important to adapt the design of die casting parts quickly and inexpensively by taking into account the material and process local constraints. In this work, a methodological approach which permits to predict mechanical properties as a function of material and process variability based on an experimental/ statistical study on the effect of the variability of the primary factors of alloying elements contents (Si, Cu and Mg) and HPDC process parameters (casting temperature and injection pressure) on mechanical properties of die cast aluminium alloys has been proposed. The microstructural features and the porosity level were also investigated and assessed. This approach has resulted in statistical design tool that will allow designers to make changes to the design of their casting and to industrialize them outside Europe.
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Imane Outmani. Caractérisation des variabilités Matériaux/ Process pour une convergence produit de fonderie par approche prédictive. Mécanique [physics.med-ph]. Ecole nationale supérieure d'arts et métiers - ENSAM, 2017. Français. ⟨NNT : 2017ENAM0007⟩. ⟨tel-01511882⟩

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