The development of a virtual prototype should integrate the simulation carried out using the casting process simulation tool and the numerical response, based on FEM code, of the component at in-service conditions.

The main need for this integrated simulation approach is that a component’s material microstructure, including micro- and macro-defects, is often the reason for an earlier than expected in-service failure of the component.

In the specific case of Al-Si alloys, the mechanical properties are determined by the ?-Al phase properties, by the grain size, by the eutectic silicon characteristics, as well as by the presence of secondary and inter-metallic phases. Generally speaking, a component characterized by a fine microstructure, with no brittle phases, presents better mechanical properties if compared to a component with a coarse structure, high SDAS values and with the presence of acicular eutectic silicon crystals.

A wholesome representation of the component’s mechanical properties along the manufacturing process chain, both at the macro- (residual stresses, local mechanical properties, casting defects) and micro- level (morphology, phase types, SDAS values, grain size), is the starting block for reliable structural design.  The simulation process carried out for this particular study is outlined in the figures above.