Change search
Link to record
Permanent link

Direct link
BETA
Publications (10 of 34) Show all publications
Jansson, J., Olofsson, J. & Salomonsson, K. (2019). On the use of heterogeneous thermomechanical and thermophysical material properties in finite element analyses of cast components. In: IOP Conference Series: Materials Science and Engineering. Paper presented at Joint 5th International Conference on Advances in Solidification Processes, ICASP 2019, and 5th International Symposium on Cutting Edge of Computer Simulation of Solidification, Casting and Refining, CSSCR 2019, 17-21 June 2019. Institute of Physics (IOP), 529(1), Article ID 012076.
Open this publication in new window or tab >>On the use of heterogeneous thermomechanical and thermophysical material properties in finite element analyses of cast components
2019 (English)In: IOP Conference Series: Materials Science and Engineering, Institute of Physics (IOP), 2019, Vol. 529, no 1, article id 012076Conference paper, Published paper (Refereed)
Abstract [en]

Cast components generally show a heterogeneous distribution of material properties, caused by variations in the microstructure that forms during solidification. Variations caused by the casting process are not commonly considered in structural analyses, which might result in manufacturing of sub-optimised components with unexpected in-use behaviour. In this paper, we present a methodology which can be used to consider both thermomechanical and thermophysical variations using finite element analyses in cast components. The methodology is based on process simulations including microstructure modelling and correlations between microstructural features and material properties. Local material data are generated from the process simulation results, which are integrated into subsequent structural analyses. In order to demonstrate the methodology, it is applied to a cast iron cylinder head. The heterogeneous distribution of material properties in this component is investigated using experimental methods, demonstrating local variations in both mechanical and physical behaviour. In addition, the strength-differential effect on tensile and compressive behaviour of cast iron is considered in the modelling. The integrated simulation methodology presented in this work is relevant to both design engineers, production engineers as well as material scientists, in order to study and better understand how local variations in microstructure might influence the performance and behaviour of cast components under in-use conditions. 

Place, publisher, year, edition, pages
Institute of Physics (IOP), 2019
Series
IOP Conference Series: Materials Science and Engineering, ISSN 1757-8981 ; 529:1
Keywords
Cast iron, Cutting tools, Cylinder heads, Microstructure, Refining, Solidification, Structural analysis, Experimental methods, Heterogeneous distributions, Integrated simulations, Material scientists, Microstructural features, Microstructure modelling, Strength-differential effects, Thermophysical material properties, Finite element method
National Category
Metallurgy and Metallic Materials
Identifiers
urn:nbn:se:hj:diva-45335 (URN)10.1088/1757-899X/529/1/012076 (DOI)2-s2.0-85067891373 (Scopus ID)
Conference
Joint 5th International Conference on Advances in Solidification Processes, ICASP 2019, and 5th International Symposium on Cutting Edge of Computer Simulation of Solidification, Casting and Refining, CSSCR 2019, 17-21 June 2019
Available from: 2019-07-12 Created: 2019-07-12 Last updated: 2019-07-12Bibliographically approved
Olofsson, J., Salomonsson, K., Dahle, A. & Mathiesen, R. H. (2019). Three-dimensional study of nodule clustering and heterogeneous strain localization for tailored material properties in ductile iron. In: IOP Conference Series: Materials Science and Engineering. Paper presented at Joint 5th International Conference on Advances in Solidification Processes, ICASP 2019 and 5th International Symposium on Cutting Edge of Computer Simulation of Solidification, Casting and Refining, CSSCR 2019, 17-21 June 2019. Institute of Physics (IOP), 529(1), Article ID 012078.
Open this publication in new window or tab >>Three-dimensional study of nodule clustering and heterogeneous strain localization for tailored material properties in ductile iron
2019 (English)In: IOP Conference Series: Materials Science and Engineering, Institute of Physics (IOP), 2019, Vol. 529, no 1, article id 012078Conference paper, Published paper (Refereed)
Abstract [en]

Tailored heterogeneous distributions of microstructural features enable extraordinary material performance in biological and physiological structures such as trees, the aortic arch, human teeth and dinosaur skulls. In ductile iron, a heterogeneous distribution in size and morphology of graphite nodules and variations of the fractions of ferrite and pearlite are created during solidification, and varies as a function of parameters such as local cooling rate, segregation and flow. In the current work, the size distribution as well as the orientation and relation between graphite nodules is obtained by a three-dimensional reconstruction of a ductile iron microstructure from X-ray tomography. The effect of the nodule morphology and clustering on the localization of plastic strains is studied numerically using finite element analysis of the reconstructed microstructure. Real castings have a variation in geometry, solidification conditions and are subjected to variations in loads. A framework for optimized geometry and solidification conditions in order to design and deliver castings with tailored local material performance is proposed.

Place, publisher, year, edition, pages
Institute of Physics (IOP), 2019
Series
IOP Conference Series: Materials Science and Engineering, ISSN 1757-8981 ; 529:1
Keywords
Biological materials, Cutting tools, Ductility, Graphite, Iron, Microstructure, Morphology, Refining, Strain, Heterogeneous distributions, Heterogeneous strain, Material performance, Microstructural features, Optimized geometries, Physiological structures, Solidification condition, Three-dimensional reconstruction, Solidification
National Category
Metallurgy and Metallic Materials
Identifiers
urn:nbn:se:hj:diva-45336 (URN)10.1088/1757-899X/529/1/012078 (DOI)2-s2.0-85067865845 (Scopus ID)
Conference
Joint 5th International Conference on Advances in Solidification Processes, ICASP 2019 and 5th International Symposium on Cutting Edge of Computer Simulation of Solidification, Casting and Refining, CSSCR 2019, 17-21 June 2019
Available from: 2019-07-12 Created: 2019-07-12 Last updated: 2019-07-12Bibliographically approved
Ghasemi, R., Elmquist, L., Ghassemali, E., Salomonsson, K. & Jarfors, A. E. .. (2018). Abrasion resistance of lamellar graphite iron: Interaction between microstructure and abrasive particles. Tribology International, 120, 465-475
Open this publication in new window or tab >>Abrasion resistance of lamellar graphite iron: Interaction between microstructure and abrasive particles
Show others...
2018 (English)In: Tribology International, ISSN 0301-679X, E-ISSN 1879-2464, Vol. 120, p. 465-475Article in journal (Refereed) Published
Abstract [en]

This study focuses on abrasion resistance of Lamellar Graphite Iron (LGI) using microscratch test under constant and progressive load conditions. The interactions between a semi-spherical abrasive particle, cast iron matrix and graphite lamellas were physically simulated using a sphero-conical indenter. The produced scratches were analysed using LOM and SEM to scrutinise the effect of normal load on resulting scratch depth, width, frictional force, friction coefficient and deformation mechanism of matrix during scratching. Results showed a significant matrix deformation, and change both in frictional force and friction coefficient by increase of scratch load. Furthermore, it was shown how abrasive particles might produce deep scratches with severe matrix deformation which could result in graphite lamella's coverage and thereby deteriorate LGI's abrasion resistance.

Place, publisher, year, edition, pages
Elsevier, 2018
Keywords
Lamellar graphite cast iron; Abrasion resistance; Scratch test; Microstructure; Pearlite deformation
National Category
Metallurgy and Metallic Materials
Identifiers
urn:nbn:se:hj:diva-38473 (URN)10.1016/j.triboint.2017.12.046 (DOI)000428102900046 ()2-s2.0-85041480396 (Scopus ID)
Available from: 2018-01-12 Created: 2018-01-12 Last updated: 2019-02-15Bibliographically approved
Jansson, J., Gustafsson, T., Salomonsson, K., Olofsson, J., Johansson, J., Appelsved, P. & Palm, M. (2018). An anisotropic non-linear material model for glass fibre reinforced plastics. Composite structures, 195, 93-98
Open this publication in new window or tab >>An anisotropic non-linear material model for glass fibre reinforced plastics
Show others...
2018 (English)In: Composite structures, ISSN 0263-8223, E-ISSN 1879-1085, Vol. 195, p. 93-98Article in journal (Refereed) Published
Abstract [en]

This paper aims to present a methodology to predict the anisotropic and non-linear behaviour of glass fibre reinforced plastics using finite element methods. A material model is implemented in order to remedy the need of multiple material definitions, and to control the local plastic behaviour as a function of the fibre orientation. Injection moulding simulations traditionally provide second order orientation tensors, which are considered together with a homogenization scheme to compute local material properties. However, in the present study, fourth order tensors are used in combination with traditional methods to provide more accurate material properties. The elastic and plastic response of the material model is optimized to fit experimental test data, until simulations and experiments overlap. The proposed material model can support design engineers in making more informed decisions, allowing them to create smarter products without the need of excessive safety factors, leading to reduced component weight and environmental impact. 

Place, publisher, year, edition, pages
Elsevier, 2018
Keywords
Calibration, Fibre orientation, GFRP, Local material properties, Anisotropy, Elastomers, Environmental impact, Finite element method, Glass fibers, Injection molding, Product design, Reinforced plastics, Reinforcement, Safety factor, Tensors, Fourth-order tensors, Homogenization scheme, Multiple materials, Nonlinear behaviours, Nonlinear materials, Fiber reinforced plastics
National Category
Materials Engineering
Identifiers
urn:nbn:se:hj:diva-39386 (URN)10.1016/j.compstruct.2018.04.044 (DOI)000432491400009 ()2-s2.0-85045766757 (Scopus ID)
Available from: 2018-05-09 Created: 2018-05-09 Last updated: 2019-02-14Bibliographically approved
Svensson, I. L. & Salomonsson, K. (2018). Mathematical characterization of the tensile deformation curve of cast iron materials. Paper presented at 11th International Symposium on the Science and Processing of Cast Iron, SPCI-XI 2017, Jönköping, Sweden, 4-7 September 2017. Materials Science Forum, 925, 444-450
Open this publication in new window or tab >>Mathematical characterization of the tensile deformation curve of cast iron materials
2018 (English)In: Materials Science Forum, ISSN 0255-5476, E-ISSN 1662-9752, Vol. 925, p. 444-450Article in journal (Refereed) Published
Abstract [en]

The manufacturing process gives cast iron castings properties which are dependent on component design, metallurgy and casting method. Factors such as local wall thickness influences the coarseness and type of microstructure and the castings will have local properties depending on the local metallurgical and thermal history. The stress/strain behaviour of cast materials is typically determined by performing a tensile test in a tensile test machine. The deformation behaviour will normally be determined by two mechanisms, namely, elastic and plastic phenomena. The plastic behaviour is based on dislocation movements in the lattice. Commonly, the deformation history of cast iron involves elastic, plastic and crack phases. The cast iron material has a complex microstructure and first order equations cannot be used to predict the deformation during loading. Until methods have been developed, the characterization of complex microstructure materials such as cast iron has to be determined by use of empirical methods. The empirical methods have to couple the internal microstructure and composition of the material with deformation phenomena during loading. The paper will show a method to characterize tensile test curves of cast iron materials which can be used to couple deformation phenomena with for example microstructure. The equations are aimed to make the tensile test curve ready for curve fitting and optimization in two steps. Each stress/strain curve is like a finger print of the material and requires well performed tests and some advices are given. The paper also wants to encourage researchers and people working with tensile testing to get out more of their effort to measure strength of cast iron materials and connect the result to the microstructure of the specimens. 

Place, publisher, year, edition, pages
Trans Tech Publications, 2018
Keywords
Curve fitting methods, Evaluation of, Mathematical curve fitting, Microstructure dependent deformation, Microstructure dependent prediction of tensile test curve, Tensile test curve, Curve fitting, Deformation, Iron compounds, Metallurgy, Microstructure, Stress-strain curves, Tensile testing, Complex microstructures, First order equations, Internal microstructure, Manufacturing process, Mathematical characterization, Mathematical curves, Cast iron
National Category
Materials Engineering
Identifiers
urn:nbn:se:hj:diva-41281 (URN)10.4028/www.scientific.net/MSF.925.444 (DOI)XYZ ()2-s2.0-85050025596 (Scopus ID)9783035710557 (ISBN)
Conference
11th International Symposium on the Science and Processing of Cast Iron, SPCI-XI 2017, Jönköping, Sweden, 4-7 September 2017
Available from: 2018-08-28 Created: 2018-08-28 Last updated: 2019-02-15Bibliographically approved
Kasvayee, K. A., Ghassemali, E., Salomonsson, K., Sujakhu, S., Castagne, S. & Jarfors, A. E. .. (2018). Microstructural strain mapping during in-situ cyclic testing of ductile iron. Materials Characterization, 140, 333-339
Open this publication in new window or tab >>Microstructural strain mapping during in-situ cyclic testing of ductile iron
Show others...
2018 (English)In: Materials Characterization, ISSN 1044-5803, E-ISSN 1873-4189, Vol. 140, p. 333-339Article in journal (Refereed) Published
Abstract [en]

This paper focuses on local strain distribution in the microstructure of high silicon ductile iron during cyclic loading. In-situ cyclic test was performed on compact-tension (CT) samples inside the scanning electron microscope (SEM) to record the whole deformation and obtain micrographs for microstructural strain measurement by means of digital image correlation (DIC) technique. Focused ion beam (FIB) milling was used to generate speckle patterns necessary for DIC measurement. The equivalent Von Mises strain distribution was measured in the microstructure at the maximum applied load. The results revealed a heterogeneous strain distribution at the microstructural level with higher strain gradients close to the notch of the CT sample and accumulated strain bands between graphite particles. Local strain ahead of the early initiated micro-cracks was quantitatively measured, showing high strain localization, which decreased by moving away from the micro-crack tip. It could be observed that the peak of strain in the field of view was not necessarily located ahead of the micro-cracks tip which could be because of the (i) strain relaxation due to the presence of other micro-cracks and/or (ii) presence of subsurface microstructural features such as graphite particles that influenced the strain concentration on the surface.

Place, publisher, year, edition, pages
Elsevier, 2018
Keywords
Digital image correlation, Fatigue, FIB_DIC, Micro-crack, Spherical graphite iron, Computerized tomography, Concrete aggregates, Cyclic loads, Ductility, Fatigue of materials, Graphite, Image analysis, Ion beams, Iron, Microstructural evolution, Scanning electron microscopy, Speckle, Strain measurement
National Category
Metallurgy and Metallic Materials
Identifiers
urn:nbn:se:hj:diva-36851 (URN)10.1016/j.matchar.2018.04.017 (DOI)00043327280003 ()2-s2.0-85045698106 (Scopus ID)JTHMaterialIS (Local ID)JTHMaterialIS (Archive number)JTHMaterialIS (OAI)
Funder
Knowledge Foundation, 20100280
Available from: 2017-08-14 Created: 2017-08-14 Last updated: 2019-02-14Bibliographically approved
Olofsson, J., Cenni, R., Cova, M., Bertuzzi, G., Salomonsson, K. & Johansson, J. (2018). Multidisciplinary shape optimization of ductile iron castings by considering local microstructure and material behaviour. Structural and multidisciplinary optimization (Print), 57(5), 1889-1903
Open this publication in new window or tab >>Multidisciplinary shape optimization of ductile iron castings by considering local microstructure and material behaviour
Show others...
2018 (English)In: Structural and multidisciplinary optimization (Print), ISSN 1615-147X, E-ISSN 1615-1488, Vol. 57, no 5, p. 1889-1903Article in journal (Refereed) Published
Abstract [en]

During the casting process and solidification of ductile iron castings, a heterogeneous microstructure is formed throughout the casting. This distribution is strongly influenced by the item geometry and the process related factors, as chemical composition and local solidification conditions. Geometrical changes to the geometry of the casting thus alters the local mechanical behavior and properties, as well as the distribution of stresses and strains when the casting is subjected to load. In order to find an optimal geometry, e.g. with reduced weight and increased load-bearing capacity, this interdependency between geometry and local material behavior needs to be considered and integrated into the optimization method. In this contribution, recent developments in the multidisciplinary integration of casting process simulation, solidification and microstructure modelling, microstructure-based material characterization, finite element structural analyses with local material behavior and structural optimization techniques are presented and discussed. The effect and relevance of considering the local material behavior in shape optimization of ductile iron castings is discussed and evidenced by an industrial application. It is shown that by adopting a multidisciplinary optimization approach by integration of casting simulation and local material behavior into shape optimization, the potential of the casting process to obtain components with high performance and reliability can be enabled and utilized. 

Place, publisher, year, edition, pages
Springer, 2018
Keywords
Casting simulation, Component casting, Local material properties, Shape optimization, Cast iron, Characterization, Codes (symbols), Ductility, Elasticity, Finite element method, Geometry, Iron, Microstructure, Solidification, Structural design, Structural optimization, Casting process simulation, Casting simulations, Finite element structural analysis, Heterogeneous microstructure, Material characterizations, Multi-disciplinary optimizations, Performance and reliabilities
National Category
Metallurgy and Metallic Materials
Identifiers
urn:nbn:se:hj:diva-39002 (URN)10.1007/s00158-018-1929-z (DOI)000431264000006 ()2-s2.0-85042078871 (Scopus ID)JTHMaterialIS, JTHProduktutvecklingIS (Local ID)JTHMaterialIS, JTHProduktutvecklingIS (Archive number)JTHMaterialIS, JTHProduktutvecklingIS (OAI)
Available from: 2018-03-16 Created: 2018-03-16 Last updated: 2019-02-14Bibliographically approved
Salomonsson, K. & Jarfors, A. E. .. (2018). Three-dimensional microstructural characterization of cast iron alloys for numerical analyses. Paper presented at 11th International Symposium on the Science and Processing of Cast Iron, SPCI-XI 2017, Jönköping, Sweden, 4-7 September 2017. Materials Science Forum, 925, 427-435
Open this publication in new window or tab >>Three-dimensional microstructural characterization of cast iron alloys for numerical analyses
2018 (English)In: Materials Science Forum, ISSN 0255-5476, E-ISSN 1662-9752, Vol. 925, p. 427-435Article in journal (Refereed) Published
Abstract [en]

In this paper, we aim at characterizing three different cast iron alloys and their microstructural features, namely lamellar, compacted and nodular graphite iron. The characterization of microscopic features is essential for the development of methods to optimize the behavior of cast iron alloys; e.g. maximize thermal dissipation and/or maximize ductility while maintaining strength. The variation of these properties is commonly analyzed by metallography on two-dimensional representations of the alloy. However, more precise estimates of the morphologies and material characteristics are obtained by three-dimensional reconstruction of microstructures. The use of X-ray microtomography provides an excellent tool to generate high resolution threedimensional microstructure images. The characteristics of the graphite constituent in the microstructure, including the size, shape and connectivity, were analyzed for the different cast iron alloys. It was observed that the lamellar and compacted graphite iron alloys have relatively large connected graphite morphologies, as opposed to ductile iron where the graphite is present as nodules. The results of the characterization for the different alloys were ultimately used to generate finite element models.

Place, publisher, year, edition, pages
Trans Tech Publications, 2018
Keywords
Cast iron, Characterization, Microstructure, Tomography, X-ray, Ductility, Graphite, Microstructural evolution, Nodular iron, X rays, Compacted graphite iron, Material characteristics, Micro-structural characterization, Microscopic features, Microstructural features, Three-dimensional microstructures, Three-dimensional reconstruction, X ray microtomography
National Category
Materials Engineering
Identifiers
urn:nbn:se:hj:diva-41278 (URN)10.4028/www.scientific.net/MSF.925.427 (DOI)XYZ ()2-s2.0-85050017657 (Scopus ID)9783035710557 (ISBN)
Conference
11th International Symposium on the Science and Processing of Cast Iron, SPCI-XI 2017, Jönköping, Sweden, 4-7 September 2017
Funder
Knowledge Foundation
Available from: 2018-08-28 Created: 2018-08-28 Last updated: 2019-02-15Bibliographically approved
Olofsson, J., Salomonsson, K., Johansson, J. & Amouzgar, K. (2017). A methodology for microstructure-based structural optimization of cast and injection moulded parts using knowledge-based design automation. Advances in Engineering Software, 109, 44-52
Open this publication in new window or tab >>A methodology for microstructure-based structural optimization of cast and injection moulded parts using knowledge-based design automation
2017 (English)In: Advances in Engineering Software, ISSN 0965-9978, E-ISSN 1873-5339, Vol. 109, p. 44-52Article in journal (Refereed) Published
Abstract [en]

The local material behaviour of cast metal and injection moulded parts is highly related to the geometrical design of the part as well as to a large number of process parameters. In order to use structural optimization methods to find the geometry that gives the best possible performance, both the geometry and the effect of the production process on the local material behaviour thus has to be considered.

In this work, a multidisciplinary methodology to consider local microstructure-based material behaviour in optimizations of the design of engineering structures is presented. By adopting a knowledge-based industrial product realisation perspective combined with a previously presented simulation strategy for microstructure-based material behaviour in Finite Element Analyses (FEA), the methodology integrates Computer Aided Design (CAD), casting and injection moulding simulations, FEA, design automation and a multi-objective optimization scheme into a novel structural optimization method for cast metal and injection moulded polymeric parts. The different concepts and modules in the methodology are described, their implementation into a prototype software is outlined, and the application and relevance of the methodology is discussed.

Place, publisher, year, edition, pages
Elsevier, 2017
Keywords
Component casting, Injection moulding, Design automation, Knowledge based engineering, Finite element analysis, Multi-objective optimization
National Category
Metallurgy and Metallic Materials Production Engineering, Human Work Science and Ergonomics
Identifiers
urn:nbn:se:hj:diva-35390 (URN)10.1016/j.advengsoft.2017.03.003 (DOI)000400217700004 ()2-s2.0-85016937770 (Scopus ID)
Available from: 2017-04-20 Created: 2017-04-20 Last updated: 2018-08-17Bibliographically approved
Salomonsson, K. & Olofsson, J. (2017). Analysis of Localized Plastic Strain in Heterogeneous Cast Iron Microstructures Using 3D Finite Element Simulations. In: Paul Mason, Charles R Fisher, Ryan Glamm, Michele V Manuel, Georg J Schmitz, Amarendra K Singh, Alejandro Strachan (Ed.), Proceedings of the 4th World Congress on Integrated Computational Materials Engineering, ICME 2017: . Paper presented at 4th World Congress on Integrated Computational Materials Engineering, ICME 2017, Ypsilanti, United States, 21-25 May 2017 (pp. 217-225). Cham: Springer
Open this publication in new window or tab >>Analysis of Localized Plastic Strain in Heterogeneous Cast Iron Microstructures Using 3D Finite Element Simulations
2017 (English)In: Proceedings of the 4th World Congress on Integrated Computational Materials Engineering, ICME 2017 / [ed] Paul Mason, Charles R Fisher, Ryan Glamm, Michele V Manuel, Georg J Schmitz, Amarendra K Singh, Alejandro Strachan, Cham: Springer, 2017, p. 217-225Conference paper, Published paper (Refereed)
Abstract [en]

The design and production of light structures in cast iron with high static and fatigue performance is of major interest in e.g. the automotive area. Since the casting process inevitably leads to heterogeneous solidification conditions and variations in microstructural features and material properties, the effects on multiple scale levels needs to be considered in the determination of the local fatigue performance. In the current work, microstructural features of different cast irons are captured by use of micro X-ray tomography, and 3D finite element models generated. The details of the 3D microstructure differ from the commonly used 2D representations in that the actual geometry is captured and that there is not a need to compensate for 3D-effects. The first objective with the present study is to try and highlight certain aspects at the micro scale that might be the underlying cause of fatigue crack initiation, and ultimately crack propagation, under fatigue loading for cast iron alloys. The second objective is to incorporate the gained knowledge about the microstructural behavior into multi-scale simulations at a structural length scale, including the local damage level obtained in the heterogeneous structure subjected to fatigue load.

Place, publisher, year, edition, pages
Cham: Springer, 2017
Series
Minerals Metals & Materials Series, E-ISSN 2367-1181
Keywords
Cast iron; Microstructure; X-ray tomography; Characterization
National Category
Metallurgy and Metallic Materials
Identifiers
urn:nbn:se:hj:diva-38957 (URN)10.1007/978-3-319-57864-4\_20 (DOI)000424820100020 ()2-s2.0-85034665479 (Scopus ID)9783319578637 (ISBN)9783319578644 (ISBN)
Conference
4th World Congress on Integrated Computational Materials Engineering, ICME 2017, Ypsilanti, United States, 21-25 May 2017
Available from: 2018-03-05 Created: 2018-03-05 Last updated: 2018-09-03Bibliographically approved
Organisations
Identifiers
ORCID iD: ORCID iD iconorcid.org/0000-0003-0899-8939

Search in DiVA

Show all publications