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In automotive cylinder heads, thermomechanical fatigue (TMF) leads to crack initiation within the critical loaded sections. This effect becomes even more relevant in lost foam cast cylinder heads since its system-dependent porosity shows a significant influence on the lifetime under TMF loading. This work covers the identification of a criterion for crack initiation in order to provide the basis for an effective quality control with improved statistical safety by nondestructive testing. Specimens extracted from lost foam cylinder heads were investigated by uniaxial TMF tests, X-ray micro computer tomography (μCT), and scanning electron microscopy (SEM). Due to pore analyses on a global and local scale, it is concluded that pore networks are crucial for crack initiation. Thus, a tool for computation of pore accumulations from μCT data containing interaction criteria by Murakami was developed in order to assess the crack origin. The consideration of pore accumulations significantly improves the predictive accuracy compared to the consideration of single pores.

Thermomechanical Fatigue of Lost Foam Cast Al–Si Cylinder Heads—Assessment of Crack Origin Based on the Evaluation of Pore Distribution