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Publications (10 of 29) Show all publications
Olofsson, J., Bjurenstedt, A. & Seifeddine, S. (2019). On the effects of defects and imperfections on tensile toughness of a secondary aluminium alloy. In: Murat Tiryakioḡlu, William Griffiths, Mark Jolly (Ed.), Shape casting: 7th International Symposium Celebrating Prof. John Campbell's 80th Birthday. Paper presented at Shape casting : 7th International Symposium Celebrating Prof. John Campbell's 80th Birthday (pp. 131-141). Springer
Open this publication in new window or tab >>On the effects of defects and imperfections on tensile toughness of a secondary aluminium alloy
2019 (English)In: Shape casting: 7th International Symposium Celebrating Prof. John Campbell's 80th Birthday / [ed] Murat Tiryakioḡlu, William Griffiths, Mark Jolly, Springer, 2019, p. 131-141Conference paper, Published paper (Refereed)
Abstract [en]

In order to design and produce high-quality castings with reliable performance, the effect of the melt handling and melt quality during different processing stages needs to be understood and controlled, and numerical methods to provide correct input data to structural analyses of castings enabled. This paper aims to investigate tensile properties, in particular tensile toughness, of a secondary high-pressure die casting (HPDC) aluminium alloy with different levels of defects and imperfections. The melt, which was transported in liquid state from the smelter to the foundry, has been sampled after different holding times by casting into Y-blocks. Tensile testing was performed, and the levels of defects and imperfections were characterized using measurements of porosity, bifilm index, density index, sludge factor and the amount of iron-rich intermetallics. Two different quality indices have been evaluated, and a method to apply the results in simulations of damage in a casting, containing defects, subjected to load is demonstrated. 

Place, publisher, year, edition, pages
Springer, 2019
Series
Minerals, Metals and Materials Series, ISSN 2367-1181, E-ISSN 2367-1696
Keywords
Component casting, Defects, Quality index, Shape casting, Toughness, Die casting, Numerical methods, Tensile testing, High pressure die casting, High quality castings, Measurements of, Processing stage, Quality indices, Reliable performance, Tensile toughness, Quality control
National Category
Metallurgy and Metallic Materials
Identifiers
urn:nbn:se:hj:diva-43568 (URN)10.1007/978-3-030-06034-3_13 (DOI)2-s2.0-85064063515 (Scopus ID)9783030060336 (ISBN)9783030060343 (ISBN)
Conference
Shape casting : 7th International Symposium Celebrating Prof. John Campbell's 80th Birthday
Available from: 2019-05-02 Created: 2019-05-02 Last updated: 2019-05-02Bibliographically approved
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
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
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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
Malakizadi, A., Ghasemi, R., Behring, C., Olofsson, J., Jarfors, A. E. .., Nyborg, L. & Krajnik, P. (2018). Effects of workpiece microstructure, mechanical properties and machining conditions on tool wear when milling compacted graphite iron. Wear, 410-411, 190-201
Open this publication in new window or tab >>Effects of workpiece microstructure, mechanical properties and machining conditions on tool wear when milling compacted graphite iron
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2018 (English)In: Wear, ISSN 0043-1648, E-ISSN 1873-2577, Vol. 410-411, p. 190-201Article in journal (Refereed) Published
Abstract [en]

The aim of the present study was to investigate the tool performance when machining compacted graphite iron (CGI) alloys. A comparison was made between solid solution strengthened CGI including various amounts of silicon (Si-CGI) and the pearlitic-ferritic CGI as a reference material. The emphasis was on examining the influence of microstructure and mechanical properties of the material on tool wear in face milling process. Machining experiments were performed on the engine-like test pieces comprised of solid solution strengthened CGI with three different silicon contents and the reference CGI alloy. The results showed up-to 50% lower flank wear when machining Si-CGI alloys, although with comparable hardness and tensile properties. In-depth analysis of the worn tool surfaces showed that the abrasion and adhesion were the dominant wear mechanisms for all investigated alloys. However, the better tool performance when machining Si-CGI alloys was mainly due to a lower amount of abrasive carbo-nitride particles and the suppression of pearlite formation in the investigated solid solution strengthened alloys.

Place, publisher, year, edition, pages
Elsevier, 2018
Keywords
Casting, CGI, Machinability, Milling, Solution hardening, Tool wear, Graphite, Iron alloys, Mechanical properties, Microstructure, Milling (machining), Pearlite, Silicon alloys, Solid solutions, Wear of materials, Compacted graphite iron, Machining conditions, Machining experiments, Microstructure and mechanical properties, Pearlite formations, Reference material, Cutting tools
National Category
Metallurgy and Metallic Materials
Identifiers
urn:nbn:se:hj:diva-41217 (URN)10.1016/j.wear.2018.07.005 (DOI)000440030600019 ()2-s2.0-85050005596 (Scopus ID)
Funder
VINNOVA, GNR 2012_137 2.4.2Knowledge Foundation, GNR 20100218
Available from: 2018-08-23 Created: 2018-08-23 Last updated: 2019-02-14Bibliographically approved
Thomser, C., Olofsson, J. & Gurevitch, V. (2018). Influence of local microstructure on stresses, durability and fracture mechanics of cast iron components. 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, 264-271
Open this publication in new window or tab >>Influence of local microstructure on stresses, durability and fracture mechanics of cast iron components
2018 (English)In: Materials Science Forum, ISSN 0255-5476, E-ISSN 1662-9752, Vol. 925, p. 264-271Article in journal (Refereed) Published
Abstract [en]

Cast iron components show a large variety of different microstructures in dependence on chemical composition, inoculation and cooling conditions. In conventional static and dynamic calculations as well as in fracture mechanics assessment of cast iron components, the influence of local microstructure on the overall behavior of the component is not considered. Usually one material dataset is applied for the whole material. The paper describes recent developments in the field of the prediction of local microstructure and its correlation to local stress-strain, fatigue durability as well as fracture toughness. The benefit of combining casting process simulation with lifetime predictions and fracture mechanics assessment is shown for selected examples. By integrating casting process simulation, microstructure modelling, local material characterization and load analysis, a simulation based approach for predicting the behavior and performance of cast iron components already during the design stage is enabled. Thus, the local assessment helps designers to assess risks and strive for light weight designs before the casting is made.

Place, publisher, year, edition, pages
Trans Tech Publications, 2018
Keywords
Cast iron, Casting process simulation, Durability, Failure assessment diagram (FAD), Fatigue, Fracture toughness, Mechanical properties, Microstructure, S-N curves, Woehler curves, Fatigue of materials, Forecasting, Fracture mechanics, Risk assessment, Chemical compositions, Failure assessment diagram, Integrating casting process, Microstructure modelling, S-N curve, Simulation based approaches, Woehler curve
National Category
Materials Engineering
Identifiers
urn:nbn:se:hj:diva-41282 (URN)10.4028/www.scientific.net/MSF.925.264 (DOI)XYZ ()2-s2.0-85050010177 (Scopus ID)JTHMaterialIS (Local ID)9783035710557 (ISBN)JTHMaterialIS (Archive number)JTHMaterialIS (OAI)
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: 2019-01-25Bibliographically approved
Olofsson, J. (2018). Local microstructure-based material performance and damage in design and finite element simulations of cast components. Journal of Computational Design and Engineering, 5(4), 419-426
Open this publication in new window or tab >>Local microstructure-based material performance and damage in design and finite element simulations of cast components
2018 (English)In: Journal of Computational Design and Engineering, ISSN 2288-4300, Vol. 5, no 4, p. 419-426Article in journal (Refereed) Published
Abstract [en]

A novel approach to incorporate local microstructure-based material performance into finite element method (FEM) simulations of cast components is presented. By adopting perspectives from natural designs as dinosaur skulls and trees, the discipline-wide approach enables accurate prediction of damage in structures based on a heterogeneous distribution of sub-scale features. It is shown that heterogeneous damage tolerance dictates the performance and failure of cast aluminum, and simulations are compared with experimental results of heterogeneous tensile samples using digital image correlation (DIC). The numerical application of the approach in the industrial product realization process of an industrial casting is demonstrated, and the applicability of the approach to understand the behavior and failure of natural as well as synthetic structures is discussed. 

Place, publisher, year, edition, pages
Elsevier, 2018
Keywords
Casting and solidification, Casting process simulation, Component casting, Damage, Finite element simulations, Modelling and simulation, Strain energy density
National Category
Metallurgy and Metallic Materials
Identifiers
urn:nbn:se:hj:diva-41271 (URN)10.1016/j.jcde.2018.02.002 (DOI)000452649100006 ()2-s2.0-85049744219 (Scopus ID)
Funder
Knowledge Foundation
Available from: 2018-08-28 Created: 2018-08-28 Last updated: 2019-01-02Bibliographically 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
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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
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/0000-0003-2671-9825

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