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(ICME) of Aluminum Solidification and Casting DISSERTATION Presented Integrated Computational Materials Engineering (ICME) of Aluminum Solidification and Casting DISSERTATION Presented in Partial Fulfillment of the Requirements for the Degree Doctor of Philosophy in the Graduate School of The Ohio State University By Colin Douglas Ridgeway Graduate Program in Materials Science and Engineering The Ohio State University 2020 Dissertation Committee: Dr. Alan A. Luo, Advisor Dr. Glenn Daehn Dr. Steve Niezgoda Dr. Roland Kawakami Copyrighted by Colin Douglas Ridgeway 2020 Abstract Traditionally, the design and eventual casting of engineering components has been plagued by the assumption of homogeneous mechanical properties across the whole of the casting. Such an assumption is rarely the case and often leads to overdesign and excessive downstream waste. To combat this, the Integrated Computation Materials Engineering (ICME) approach was implemented to provide an increased level of accuracy for the prediction of location specific properties in cast aluminum. Variable properties often result from variable cooling rates that occur in a structure resulting from cooling lines or chill blocks located within the mold package, variable alloying content and finally the defects present in the alloy. In the context of this research, variable cooling was studied using the concept of a maximum chill scenario where the heat transfer coefficient (HTC) was examined and found to develop over time. The resulting microstructure was included an extremely refined eutectic silicon within the interdendritic regions. Unique, time-dependent HTC maps were created for optimized maximum chill scenario casting conditions to provide unique cooling and solidification conditions across the whole of a casting. The effect of Magnesium on hypoeutectic Al-Si alloys Primary Dendrite Arm Spacing (PDAS) was examined next. Directional solidification experimentation was coupled with Cellular Automaton (CA) simulations to develop a model to predict the location specific PDAS within Al-Si-Mg alloys. Additionally, location specific properties are known to result from defects within the ii microstructure such oxide inclusions and porosity. These voided regions act as regions of increased stress and result in premature failure of engineered components. In this work the fluid flow, filling conditions and free surface of the molten aluminum was examined to create a new model that was accurately shown to predict the location specific defect content in a cast structure. Finally, the sum of this work was used to couple various Computer-Aided Engineering (CAE) software tools to complete the ICME approach. By coupling various commercial software, exact location specific mechanical properties were shown to be accurately predicted using a method term the CA – FEA approach. The CA – FEA approach is the first method for using physics based microstructure predictions to determine the location specific mechanical down to a cubic millimeter. iii Dedication Dedicated to my loving family: my parents Doug and Mindy Ridgeway, and my future wife, Rachael. You are my driving force. iv Acknowledgments I would first like to thank my graduate advisor, Dr. Alan A. Luo for accepting me into the Light Metals and Manufacturing Research Laboratory at The Ohio State University. Dr. Alan Luo provided me with a number of research and industrial opportunities to grow as a researcher and further my knowledge in the field of metallurgy. His expertise helped mold me into a better materials and metallurgical engineer, and for that I am thankful. Along with Dr. Luo, I want to acknowledge the guidance of Dr. Glenn Daehn and Dr. Stephen Niezgoda, both of which went above and beyond to aid me during my studies at The Ohio State University. I also want to thank and acknowledge my team in the Light Metals and Manufacturing Research Laboratory. I want to thank Dr. Andrew Klarner, Dr. Scott Sutton, Dr. Zhi Liang and Dr. Emre Cinkilic for setting the ground for our laboratory and teaching me how to be a graduate student. I want to thank Xuejun Huang for his friendship and aid as we completed every part of our collegiate careers together. Thank you to Dr. Cheng Gu for the opportunities to take a deep dive into solidification and teaching me how to publish papers. Last, I would like to thank Emre Cinkilic for his great friendship, I will always look back fondly of our time together. Additionally I would like to acknowledge my research sponsors throughout my graduate research; specifically Duane Detwiler of Honda R&D Americas, and Keith Ripplinger of Honda Engineering America. I greatly appreciate the immense amount of feedback, support and direction of the past five years. Duane, Keith, and Honda afforded me the v resources and countless opportunities over the course of my PhD studies, and I want to thank them for everything they taught me along the way. I would like to conclude by thanking everyone who has helped or aided me along the way during my nine years at The Ohio State University. From my freshman year in Bradley hall to my final years in Fontana, MacQuigg and Watts, I have made countless memories. Thank you to Frank Ryan and Benson Jung who were with me every step of the way in undergrad. Thank you to Jake Phlipot who truly introduced me to metal casting for the first time. Thank you to my MSE family who introduced me to new cultures, new traditions, and supported me year after year. And finally, thank you to The Ohio State University, Go Bucks! vi Vita 2011................................................................Grandview Heights High School, Grandview Heights, Ohio 2015................................................................B.S. Department of Materials Science and Engineering, The Ohio State University 2018................................................................M.S. Department of Materials Science and Engineering, The Ohio State University 2017 to 2019………………………………..Graduate Teaching Associate, Department of Materials Science and Engineering, The Ohio State University 2015 to 2020 .................................................Graduate Research Associate, Light Metals and Manufacturing Research Laboratory, Department of Materials Science and Engineering, The Ohio State University Publications 1. C. Gu, C.D. Ridgeway, Y. Lu, E. Cinkilic, A.A. Luo. Predicting gas and shrinkage porosity in solidification microstructure: a coupled three-dimensional cellular automaton model. Journal of Material Science and Technology. Vol. 49, Pp. 91-105 (2020) vii 2. C.D. Ridgeway, K. Ripplinger, D. Detwiler, A.A. Luo. Prediction of Entrained Oxide Inclusions and Oxide Induced Defects during Directional flow in Aluminum Casting. AFS Transactions. Vol. 128 (2020) 3. C.D. Ridgeway, C. Gu, A.A. Luo, Predicting primary dendrite arm spacing in Al-Si- Mg alloys: effect of Mg alloying. Journal of Materials Science. Vol. 54, Issue 13. Pp. 9907-9920. (2019) 4. C. Gu, C.D. Ridgeway, A.A. Luo. Examination of dendritic Growth During Solidification of Ternary Alloys via Novel Quantitative 3D Cellular Automaton Model. Metallurgical and Materials Transactions B. Vol. 50, Issue 1. Pp. 123-135. (2019) 5. C. Gu, Y. Lu, C.D. Ridgeway, E. Cinkilic, A.A. Luo. Three-dimensional cellular automaton simulation of coupled hydrogen porosity and microstructure during solidification of ternary alloys. Scientific Reports, 9, 13099. (2019) 6. E. Cinkilic, C.D. Ridgeway, X. Yan, A.A. Luo, A Formation Map of Iron-Containing Intermetallic Phases in recycled Cast Aluminum Alloys. Metallurgical and Materials Transactions A. Vol. 50, Issue 12. Pp. 5945-5956 (2019) Fields of Study Major Field: Materials Science and Engineering viii Table of Contents Abstract ............................................................................................................................... ii Dedication .......................................................................................................................... iv Acknowledgments............................................................................................................... v Vita .................................................................................................................................... vii List of Tables ................................................................................................................... xvi List of Figures ................................................................................................................. xvii Chapter 1: Introduction ...................................................................................................... 1 1.1 Motivation of Research ............................................................................................. 1 1.1.1 Vehicle Lightweighting ...................................................................................... 4 1.1.2 Location Specific Properties ............................................................................... 6 1.1.3 Research Objective ........................................................................................... 10 1.2 Dissertation outline ................................................................................................. 11 Chapter 2: Background: Solidification and Casting ......................................................... 13 2.1 Factors Affecting Solidification ......................................................................... 13 2.1.1 Casting Methodologies and Heat Transfer ....................................................... 14 2.1.2 General
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