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<p>Lightweighting in the automotive industry has driven the emergence of large aluminum castings for body structures, often referred to as “giga castings.” The increasing use of aluminum giga castings in critical structures requires improved quality, with more reliable and quantifiable performance in both safety and durability. Aluminum casting processing is very complex and involves many competing mechanisms, multi-physics phenomena, and potentially large uncertainties. One of the most effective ways to optimize the design and manufacturing processes of aluminum giga castings to achieve the desirable mechanical properties is through the development and exploitation of robust and accurate multi-scale computational material models. This paper reports on an integrated computational materials engineering (ICME) approach for through-process modeling of local tensile properties of an aluminum giga casting using GM virtual cast component development (VCCD) tools.</p>

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Prediction of Local Tensile Properties in an Aluminum Giga Casting

  • 期刊论文

  • 发表日期：

    2025年6月17日

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  • Qigui Wang,
  • Andy Wang,
  • Jason Coryell

摘要

Lightweighting in the automotive industry has driven the emergence of large aluminum castings for body structures, often referred to as “giga castings.” The increasing use of aluminum giga castings in critical structures requires improved quality, with more reliable and quantifiable performance in both safety and durability. Aluminum casting processing is very complex and involves many competing mechanisms, multi-physics phenomena, and potentially large uncertainties. One of the most effective ways to optimize the design and manufacturing processes of aluminum giga castings to achieve the desirable mechanical properties is through the development and exploitation of robust and accurate multi-scale computational material models. This paper reports on an integrated computational materials engineering (ICME) approach for through-process modeling of local tensile properties of an aluminum giga casting using GM virtual cast component development (VCCD) tools.