Fundamental Study on Defect-Allowed Design Method of Aluminum Alloy Die Castings for Efficient Recycle

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To realize an efficient recycle of aluminum ally die castings, we found some fundamental knowledge on the development of fatigue life estimation method considering the casting defects, that is, porosity. It was shown that the clustered shrinkage cavity sometimes appeared and drastically reduced the fatigue life. Its formation mechanism and mechanical effects were also clarified from the finite element analyses based on X-ray CT or optical microscope images. Moreover, a three-dimensional strain measurement method was developed, and its availability was examined.