Quantitative 3D Characterization of Solidification Structure and Defect Evolution in Al Alloys

Abstract

Geometrically complex, as-cast, aluminum alloy components offer substantial economic and design advantages as compared to many thermo-mechanical processing routes. However, the occurrence of potential defects, including porosity, intermetallics and hot-tears, remains an issue. Using these three defects as examples, recent developments in the methodologies for quantifying defect evolution and microstructure using 3D images captured in situ via X-ray micro-tomography are discussed. It is demonstrated that 3D quantification techniques can provide significant new insight into the mechanisms controlling defect formation, and how microstructure morphology affects component performance.