A validated through process model to predict the fatigue life of a cast A356 automotive wheel

Models describing the critical steps in the manufacturing process of aluminum alloy wheels were integrated with a model of in-service loading to predict component fatigue performance, A multiscale solidification model was coupled with models of the subsequent heat treatment and machining to predict the residual stress distribution in a finished wheel. A second multiscale model was incorporated into a service model to relate the pore size and local stress state to fatigue performance. The predictions resulting from this through process modeling approach have been validated by comparisons with a series of measurements: 1) thermocouple measurements during casting; 2) characterization of pore size and distribution using X-ray microtomography and optical metallography; 3) residual strain measurements on finished wheels; 4) in-service strain measurements during a rotating bend test; and 5) in-service fatigue performance during rotating bend tests.