Metalcasting Industry Roadmap Performance-Based Reliability
a. Material Design ± This relates to the development of properties and quantitative non- destructive testing (NDT) parameters to enable design for reliability. Moving from liquid to solid is key for any casting and being able to model and predict properties is required if designers are to leverage castings and integrate them into simulation software for analysis of system functionality. A probabilistic materials property and quality model for design based upon solidification should be developed to advance casting use. Current NDT is based on workmanship and is only qualitative. This has worked largely due to the performance history of components, or by testing parts to failure. The latter is costly and time consuming. Parts can be designed using FEA, but the actual parts still need to be inspected to ensure they meet a quality threshold for performance. Providing an NDT package based on performance that is quantitative will enable advanced casting designs. Statistically sound material design static and dynamic properties that are integrated with NDT quality levels should be created. Having known properties that can be utilized during design is critical to assuring designers that a casting will achieve an expected level of performance. Unfortunately, casting property data is not readily available. Specifications often call out minimums and the material data is based on a heat sample versus actual properties within a part. Ensuring high part performance will require a much more detailed material database.
Key Tasks
x Provide more material design and process property data x Apply Failure Mode and Effects Analysis (FMEA) and Process Failure Mode Effects Analysis (PFMEA) models
x Develop high fidelity cast material datasets x Create NDT packages based on quantitative performance x Develop a probabilistic materials property and quality model for design based upon solidification
x Develop data beyond traditional tensile properties such as K1C or corrosion resistance
49 Design
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