Integration of Basic Materials Research Into the Design of Cast Components by a Multi-Scale Methodology

Abstract

We present a formal methodology to integrate basic materials research results into a design procedure for engineering components. Although the methodology is generic, we demonstrate its development and application in designing a cast automotive control arm. Specifically, we propose a multi-scale analysis whereby the local mechanisms of deformation are accounted for by an internal state variable constitutive model embedded within a non-linear elastic-plastic finite element analysis. Multiple fundamental materials research approaches at different length scales are utilized to quantify the pertinent deformation mechanisms, such as atomistic simulations, microscopy, micromechanical finite element simulations, and mechanical testing. The current methodology is a step toward a larger goal of interactively integrating basic materials science research into engineering system design. [S0094-4289(00)01903-4]