Validation of predicted residual stresses within direct chill cast magnesium alloy slab

A significant level of cold cracking has been observed within direct chill (DC) cast, high-strength magnesium alloy Elektron WE43. These cracks have been attributed to the formation of significant residual stresses during casting. A finite-element modeling (FEM) code, which is called ALSIM, has been used to predict the residual stress within the DC-cast slab. Verification of the predicted residual stress field within an 870 x 315-mm sized slab has been carried out using neutron diffraction measurements. Given that measurements in such large-scale components using diffraction measurements are particularly challenging and expensive, the efficient use of neutron diffraction measurements is emphasized. This has included the use of sectioning, allowing the residual stress within the slab to be mapped in detail