1 Thermal stress Thermal stress is caused by inconsistent cooling and inconsistent cooling at the intersection of different geometry of the casting. The formation of compressive stress at the thin wall results in residual stress in the casting. 2 Phase change stress The phase change stress is due to the phase change of certain cast aluminum alloys during the cooling process after solidification, which in turn leads to a change in the volumetric dimensions. The main reason is that the thickness of the aluminum castings is uneven, and different parts of the aluminum castings have phase changes at different times. 3 Shrinkage stress Aluminum castings are subject to tensile stress due to mold and core impediments. This stress is temporary and aluminum castings will automatically disappear when they are unpacked. But improperly opening the box, it will often cause hot cracks. In particular, cast aluminum alloys tend to produce hot cracks under such stress. The residual stress in cast aluminum alloy parts reduces the mechanical properties of the alloy and affects the machining accuracy of the casting. Residual stress in aluminum castings can be eliminated by annealing. Since the alloy has good thermal conductivity and no phase change in the cooling process, the residual stress of the aluminum casting is generally small as long as the structure design of the casting is reasonable.
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Casting stress includes thermal stress, phase change stress, and shrinkage stress. The causes of various stresses are not the same.