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The biggest influences on residual stresses in castings are the design (80%) and the casting process itself (20%). One can try to use compressive stresses as a pre-loading, like in pre-tensioned concrete. It is unusual that compressive stresses are critical. Nevertheless, even if tensile stresses are below the critical value, the casting may fail during assembly, or even worse during driving.Ĭompressive stresses are the opposite of tensile stresses and are those stresses that are induced by pushing. As a rule, tensile residual stresses are lower than this threshold value and the casting does not fail during the casting process. By reaching this value, cracking occurs and the part fails. Tensile stresses, those stresses that are induced by “pulling”, may be critical during the manufacturing process, if their value exceeds the material’s tensile strength.
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Residual stresses develop during solidification and cooling of the casting due to uneven cooling rates in the different wall thicknesses. Only by using manufacturing process simulation, is it possible to determine the distribution of residual stresses in castings and to consider these properties in the design optimization process. Their performance and weight are, among other criteria, dependent on their geometry and the casting process, especially defects like porosity and residual stresses. Cast iron engine blocks can be found in more than half of all passenger cars.