Analysis of strains in cast iron joints using finite element simulations and digital image correlation techniques

Paper in proceeding, 2012

The Metalock method is a mechanical joining technique most commonly employed in cracked castings of iron, aluminum and steel. The marine diesel engine designer MAN Diesel & Turbo uses the Metalock method for crack patching in large cast iron components. The service life of these components can thereby be extended, reducing both replacement costs and environmental impact. The purpose of this study is to investigate the mechanical behavior of the Metalock method. This was studied by full scale testing, using a non-contact deformation measurement technique known as digital image correlation (DIC), of cast iron specimens joined together by the Metalock method. Furthermore, finite element (FE) simulations were performed, and verified by experimental results, in order to study the mechanical behavior in detail and to carry out a parametric study on some of the components included in the joint. Experimental tests show that using the DIC technique gives a good possibility to verify the strain-field achieved by FE simulations and improving the understanding of the Metalock joining technique.