In situ estimation of equivalent porosity and strength of aluminum die-casting floor panel by simple loading test and finite element method

A simple estimation method of equivalent porosity and strength of scrapped aluminum die-casting floor panel is suggested in which various defects like pores can be allowed. During shop practice of processing die-casting parts, equivalent porosity is evaluated by the ratio of linear stiffness from the simple test to the analytical stiffness value. Porosity equation is derived from the inclusion theory. Then using Mori-Tanaka method the porosity value is used to find an elasto-plastic stress-strain curve for the porous material. In this paper Hollomon equation is used to describe the strain hardening effect of the die-casting material. Finally, the stress-strain curve for the porous material is used to calculate strength of die-casting part that captures the nonlinearity of the porous material. A facility die-casting floor panel is chosen to verify the proposed method. The result is accurate and adequate to the test result.