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<p>This study investigates the fatigue resistance of cast A356 aluminum alloy used in engine cylinder heads, focusing on its behavior under high temperatures. Isothermal fatigue tests were performed at fixed temperatures of 120&#xa0;°C and 280&#xa0;°C, while in-phase thermo-mechanical fatigue tests spanned a temperature range from 120 to 280&#xa0;°C. Fatigue crack growth rates were evaluated using different waveforms under displacement and load control conditions. Stress relaxation tests conducted from 75 to 280&#xa0;°C provided essential data for modeling the material’s mechanical properties. The results demonstrate that material heterogeneities and casting defects significantly impact fatigue performance, particularly at higher temperatures and under prolonged testing. The study highlights the role of porosity, which accelerates crack nucleation, reducing fatigue life by up to 50%. These findings offer valuable parameters for simulating fatigue behavior under cyclic thermal and mechanical loading, supporting the validation of Pommier and Risbet’s crack propagation model. This research contributes to developing more durable engine components capable of withstanding extreme service conditions.</p>

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Fatigue life assessment of A356 aluminum alloy used for engine cylinder head

  • 期刊论文

  • 发表日期：

    2025年3月17日

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  • M. Angeloni,
  • C. O. T. R. Ruchert,
  • W. W. Bose Filho,
  • S. Pommier

摘要

This study investigates the fatigue resistance of cast A356 aluminum alloy used in engine cylinder heads, focusing on its behavior under high temperatures. Isothermal fatigue tests were performed at fixed temperatures of 120 °C and 280 °C, while in-phase thermo-mechanical fatigue tests spanned a temperature range from 120 to 280 °C. Fatigue crack growth rates were evaluated using different waveforms under displacement and load control conditions. Stress relaxation tests conducted from 75 to 280 °C provided essential data for modeling the material’s mechanical properties. The results demonstrate that material heterogeneities and casting defects significantly impact fatigue performance, particularly at higher temperatures and under prolonged testing. The study highlights the role of porosity, which accelerates crack nucleation, reducing fatigue life by up to 50%. These findings offer valuable parameters for simulating fatigue behavior under cyclic thermal and mechanical loading, supporting the validation of Pommier and Risbet’s crack propagation model. This research contributes to developing more durable engine components capable of withstanding extreme service conditions.