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Microscale Crack Growth Studies in Rheocast A356 (Al-Si-Mg) Alloy Using Extended Finite Element Method
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Thixocasting [1] and Rheocasting [2] are the two methods available at present to produce semi solid slurry. Rheocasting unlike thixocasting does not require reheating of billet and semi solid slurry is developed from the molten metal produced in a typical die casting furnace. Rheocasting improves microstructure of die cast Al alloys significantly [2,3,4]. In the present work, Rheocasting had been performed employing cooling slope casting technique. With the help of cooling slope spherical primary crystals are produced which leads to better non dendritic microstructure. This offers improved mechanical properties such as good surface finish, net shape and enhanced accuracy [2]. Extended Finite Element Method [5,6,7] is utilized to simulate crack propagation in rheocast alloys to analyse their failure behaviour. In this research work, micro scale crack propagation in the rheocast alloys has been investigated numerically considering tensile loading condition. In this study, XFEM is used to simulate micro scale crack propagation and to study the effects of crack growth on different phases in alloy without the need of remeshing[8].
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