Findings from the FFI collaboration between Volvo Cars and Scatterin
High-pressure die-cast (HPDC) aluminum components used in automotive body structures are large, geometrically complex, and highly process-sensitive. As megacasting strategies scale, simulation-driven design depends on accurate prediction of internal residual stresses.
In this project, Volvo Cars and Scatterin investigated residual stresses in cast aluminum components using synchrotron X-ray diffraction (S-XRD), then compared measured results with finite element method (FEM) simulations.
Scatterin delivered the work as a consulting-led characterization program: planning, beamline execution, data reduction, and simulation feedback loops. The Scatterin SaaS platform was used for calibration, integration, analysis, and visualization to keep the full lifecycle traceable across teams.
Why experimental validation matters
Simulation models often simplify stress-generation mechanisms. In this project, the FEM setup focused primarily on thermal effects during quenching.
For large HPDC structural components, residual stress validation is challenging because:
- Conventional laboratory X-ray methods have limited penetration depth and are time-consuming.
- Sectioning-based preparation changes the original stress state.
To address this, synchrotron X-ray diffraction measurements were performed at PETRA III (DESY), beamline P21.2.
Figure 1. HPDC component mounted in the measurement station (diffractometer), PETRA III beamline P21.2.
High-energy synchrotron X-rays provide centimeter-level penetration in common metallic alloys, enabling fast, spatially resolved measurements in real industrial components without destructive sectioning.
Measurement scope and dataset
Four distinct areas from three separate HPDC components were analyzed. For each area:
- A 20 mm x 90 mm region was scanned.
- 11 horizontal lines were measured.
- 180 points were measured per line with 0.5 mm spacing.
- Stresses were averaged through thickness and evaluated under a plane-stress assumption.
This produced detailed residual stress maps across critical regions of the structure.
Figure 2. Distribution of von Mises stresses over a 20 mm x 90 mm area in three HPDC aluminum components.
Comparison with FEM simulations
Measured stresses were compared with predictions from the simplified FEM model.
Comparison between measured and predicted stresses showed that the simplified model did not fully reproduce the observed stress state.
Figure 3. S-XRD measured residual stresses along Z-direction compared with predicted stresses from FEM analysis.
Simulation accuracy depends on experimental validation and realistic representation of stress-generating mechanisms.
The outcome does not mean simulation cannot be applied. It shows that additional stress-generating mechanisms should be incorporated to improve predictive capability.
Process sensitivity in megacasting
The measurements also revealed stress variations linked to manufacturing parameters, including timing of ingate removal in the HPDC process.
Residual stress fields in large cast components are therefore not only geometry-dependent, but strongly process-dependent. This is a key input for next-generation model calibration and simulation validation.
Sources and acknowledgements
This work was enabled by access to the Swedish Materials Science Beamline (P21) at DESY.
The project was carried out within FFI – Strategic Vehicle Research and Innovation, a collaboration including Vinnova, Swedish Energy Agency, Trafikverket, and the Swedish automotive industry.
Public report: Testning av synkrotronljusröntgenmaterial för fordonskomponenter (Vinnova)
Original publication: Scatterin AB LinkedIn article, "Validating Residual Stress Simulations in Megacast Aluminum Components" (published February 23, 2026) via Scatterin on LinkedIn.
To learn more about Scatterin's synchrotron X-ray measurement and data analysis technology, contact: info@scatterin.com