Working Group of the Expert Committee Aluminium
Failure Mechanisms in Al Products

Due to the scarcity of resources, lightweight construction has an overriding and growing importance in many industrial sectors today. Lightweight design means designing components at the limit of the load-bearing capacity of the materials used and thus making optimum use of this. That is why component failure is now an accepted part of the development process in many areas. Failure investigations provide fundamental information for the systematic further development of high-performance lightweight systems.

Failure of aluminium components, both in development and in series products, can have a variety of causes, which generally correlate with the respective manufacturing process. The properties and manufacturing processes of aluminium alloys differ considerably from those of other metallic materials. Accordingly, special failure mechanisms are active in aluminium components, which are closely linked to the nature of the stressing of the component and its process chain. Whereas for the most important metallic material group, steel, such issues are dealt with intensively in a large number of committees, no forum has been available so far for the exchange of experts and the comprehensive solution of such problems in the field of aluminium materials. This gap is to be closed by the working group "Failure Mechanisms in Aluminium Products".

Goals

  • Long-term goal of building up a catalogue of defects for Al components in coordination with existing databases
  • Failure due to corrosion and surface treatment of Al components
  • Failure of Al components after very high load cycles (> 109)
  • Failure of welded joints made of Al materials
  • Failure due to superposition of failure mechanisms
  • Failure due to complex or multiaxial loading
  • Failure in joints between aluminium materials and aluminium materials and other material groups
  • Creep-induced failure in Al products
  • New methods that can be successfully used in failure analysis of Al products
  • Discussion of new/current failure cases that are considered typical and instructive for other participants
  • Initiation of R&D projects resulting from issues raised by the working group. The explicit aim of the working group is the constructive networking into the existing system of committees and institutions dealing with related issues. Therefore, this working group is to be lived as a joint body of the DGM and the VDI.

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