Three-Dimensional Analysis of Voids in AM60B Magnesium Tensile Bars Using Computed Tomography Imagery

In an effort to increase automobile fuel efficiency as well as decrease the output of harmful greenhouse gases, the automotive industry has recently shown increased interest in cast light metals such as magnesium alloys in an effort to increase weight savings. Currently several magnesium alloys such as AZ91 and AM60B are being used in structural applications for automobiles. However, these magnesium alloys are not as well characterized as other commonly used structural metals such as aluminum. This dissertation presents a methodology to nondestructively quantify damage accumulation due to void behavior in three dimensions in die-cast magnesium AM60B tensile bars as a function of mechanical load. Computed tomography data was acquired after tensile bars were loaded up to and including failure, and analyzed to characterize void behavior as it relates to damage accumulation. Signal and image processing techniques were used along with a cluster labeling routine to nondestructively quantify damage parameters in three dimensions. Void analyses were performed including void volume distribution characterization, nearest neighbor distance calculations, shape parameters, and volumetric renderings of voids in the alloy. The processed CT data was used to generate input files for use in finite element simulations, both two- and three-dimensional. The void analyses revealed that the overwhelming source of failure in each tensile bar was a ring of porosity within each bar, possibly due to a solidification front inherent to the casting process. The measured damage parameters related to void nucleation, growth, and coalescence were shown to contribute significantly to total damage accumulation. Void volume distributions were characterized using a Weibull function, and the spatial distributions of voids were shown to be clustered. Two-dimensional finite element analyses of the tensile bars were used to fine-tune material damage models and a three-dimensional mesh of an extracted portion of one tensile bar including voids was generated from CT data and used as input to a finite element analysis.