Microstructure-property analysis and optimization of control arm

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Microstructure-property analysis and optimization of control arm

Horstemeyer, M.F. / Osborne, R.J. / Penrod, D.E.

A microstructure-property model was developed for monotonic and cyclic fatigue loading conditions for the USAMP/USCAR Lightweight Metals Working Group as part of a CRADA with the US DOE. Both microstructure-property models were validated by experiments on the control arm. For both the monotonic and fatigue loading conditions, the microstructure-property model successfully predicted (ahead of time) where the failure location of the control arm would occur. Furthermore, the analysis was used to redesign the control arm so that a lighter weight design (26 % less weight) was stronger (50 % higher load bearing capacity) and had better fatigue resistance. Control Arm experiments were performed to validate the microstructure-property models and they also revealed the relative importance of certain parameters (material with and without paint (another curing cycle), material cast by several vendors, and material that had two different cleanliness methodologies) in the design