Abstract:Finite element analysis has been carried out to understand the effect of various processing routes and condition on the microscale deformation behavior of Al–4.5Cu–2Mg alloy. The alloy has been developed through four different routes and condition, i.e. conventional gravity casting with and without refiner, rheocasting and SIMA process. The optical microstructures of the alloy have been used to develop representative volume elements (RVEs). Two different boundary conditions have been employed to simulate the deformation behavior of the alloy under uniaxial loading. Finally, the simulated stress-strain behavior of the alloy is compared with the experimental result. It is found that the microstructural morphology has a significant impact on stress and strain distribution and load carrying capacity. The eutectic phase always carries a higher load than the α(Al) phase. The globular α(Al) grains with thinner and uniformly distributed eutectic network provide a better stress and strain distribution. Owing to this, SIMA processed alloy has better stress and strain distribution than other processes. Finally, the simulated yield strength of the alloy is verified by experiment and they have great agreement.

Key words: Al-4.5Cu-2Mg alloy; microstructure; α(Al) phase; eutectic phase; finite element analysis; micromechanical response