Characterization of microshrinkage casting defects of Al–Si alloys by X-ray computed tomography and metallography

The statistical pore size characterization by metallography in the framework of Extreme Value Statistics (EVS) is presented and applied to different sets of cast AlSi7Mg specimens. Specimen production by separate casting or by extraction from automotive cast parts is found to result in different SDAS and porosity (i.e. pore morphology and size) but did not influence the fatigue strength. The application of two equivalent pore size definitions (i.e. maximum Feret diameter and (Area)1/2) combined with the EVS approach is discussed in terms of predicted critical pore sizes and observed fatigue strengths. The role of casting pore morphology on stress concentration is investigated using the X-ray computed tomography and the finite element method.