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Possible causes for cavitations in parts made with an Al-Si eutectic alloy AK12D (AlSi12) were explored with mathematical and physical modeling with involved acoustic emission. Pores were formed from micro-cracks, which appear during the early stages of a deformation process, with the help of micro-stresses appearing at phase boundaries (Al/Si interface) due to thermal expansion. At the design stage of isothermal forgings of such products it is recommended to provide a scheme of the deformed shape, which is under uniform compression, to compensate for the inter-phase stresses.

Modeling Cavitation in ICE Pistons Made with Isothermal Forging