Modelling of the mechanical behaviour of mega cast aluminium

Research Project, 2025 – 2029

Summary
The primary goal of this industrial PhD project is to develop material models for mega cast aluminium that accurately reflect physical mechanisms and microstructural properties. These models will enhance predictive capabilities for the static, dynamic, and fatigue behaviour of mega cast components, aiding simulation-driven design processes in the automotive industry. The project involves collaboration between Chalmers University and Volvo Cars, including a parallel postdoc project focused on material characterisation. Experimental analyses will be conducted on the microstructure of cast aluminium, focusing on grain morphology and defect distribution. The main work in the proposed project will be to develop finite element models of microstructures, capturing stress-strain and fracture behaviour. Data from virtual testing of these models and mechanical testing will support machine learning to develop macroscopic fracture models accounting for statistical variations and multiaxial stress conditions. By the end of the project, we aim to have developed advanced material models capturing the fracture behaviour and mechanical response of mega cast aluminium. These models will be integrated into Volvo Cars' CAE tools for crash and fatigue analysis and validated against experiments. This will enhance car body design robustness, helping Volvo Cars leverage mega casting technology for high-performance, cost-effective, and environmentally friendly production.