Measurement of Residual Stress and Impact Behavior of Aluminum Alloy Wheels
International Journal of Metalcasting, 2026 (SCI-Expanded, Scopus)
- Publication Type: Article / Article
- Publication Date: 2026
- Doi Number: 10.1007/s40962-026-02102-2
- Journal Name: International Journal of Metalcasting
- Journal Indexes: Science Citation Index Expanded (SCI-EXPANDED), Scopus, Compendex, Academic Search Ultimate (EBSCO), Engineering Source (EBSCO)
- Keywords: aluminum alloy wheels, hole-drilling method, impact behavior, low-pressure die casting (LPDC), residual stress
- Dokuz Eylül University Affiliated: Yes
Abstract
This study investigated the effects of different heat treatment conditions on the microstructure, mechanical properties, residual stress behavior of low-pressure die-cast aluminum alloy wheels, and impact behavior of AlSi11Mg aluminum alloys through analytical and experimental approaches. Unlike the commonly studied AlSi7Mg0.3 alloys, heat-treated AlSi11Mg alloy was selected to provide an original industrial perspective for complex wheel geometries and automotive applications. Wheel samples produced under industrial conditions were evaluated using microstructural analysis, tensile and hardness testing, Charpy impact testing, residual stress simulations, and experimental hole-drilling measurements based on ASTM E837. Microstructural analyses showed that the as-cast condition exhibited coarse dendritic structures and heterogeneous morphology associated with lower mechanical performance. T6 heat treatment significantly refined the eutectic Si morphology through spheroidization, resulting in considerable improvements in hardness, ultimate tensile strength, and yield strength. Charpy impact results revealed that different cooling conditions applied to gravity cast specimens produced no significant variation in absorbed impact energy, indicating that cooling condition alone had a limited influence on impact behavior under the investigated conditions. Residual stress analyses demonstrated that the T6 heat treatment process, particularly the quenching stage, generated the highest tensile residual stresses because of severe thermal gradients. Both simulations and hole-drilling measurements identified the hub and hub–spoke transition regions as the most critical zones for residual stress accumulation. Overall, the study demonstrated that optimization of heat treatment parameters is essential for balancing mechanical performance, impact behavior, and residual stress control in industrial AlSi11Mg wheel production.