Finite Element Analysis of Crack Propagation in AlSi7%Mg0.3% Cast Alloys using Macro‐ and Micro‐Scale Levels

In this study, a computational mechanics approach has been developed to evaluate fracture toughness of an Al–Si cast alloy. Within the framework of the finite element method (FEM) CT‐test experiments have been simulated on macro‐ and micro‐scale levels with application of a cohesive zone model. Experimental CT tests have been performed and the parameters necessary for the FEM simulations (fracture energy and cohesive strength) have been determined. The estimation of fracture toughness from FEM simulations has been proposed based on a combination of crack propagation simulations on two‐length scales in one run. The proposed approach enables one to understand the effect of pores of different sizes and locations on the fracture toughness of an Al–Si cast alloy.