Annan, Kofi AhomkahNkhoma, RichardSiyasiya, Charles WitnessMostert, Roelf Johannes2023-09-082022Annan, K.A., Nkhoma, R., Siyasiya, C. et al. 2022, 'Failure analysis of thin cast A357-T6 centre shell induced by casting defect', Materials Today: Proceedings, vol. 56, pp. 2004-2009, doi : 10.1016/j.matpr.2021.11.344.2214-7853 (online)10.1016/j.matpr.2021.11.344http://hdl.handle.net/2263/92250Thin-walled Al-Si alloy precision casting components are used for various applications due to their excellent castability, corrosion resistance as well as high strength to weight ratio. It is very difficult to achieve all the set requirements due to complexity of thin-walled components through casting processes usually used in producing the aluminium alloy castings. A thin-walled shell, used as a housing unit for a component manufactured from A357-T6 alloy, failed prematurely during a torqueing process. The failed component was subjected to chemical analysis, microstructural analysis, visual examination and mechanical testing to identify the nature of the fracture and establish the primary cause of the failure. In the investigation, optical and electron microscopy, hardness and tensile tests were used to study the fracture. The examined fractured surface of the component revealed that, the fracture occurred in a brittle manner. The dominant and leading casting defect identified in the failed shell is porosity. The analysis of the results indicates that coarser grains and porosity defects led to decrease in ductility and thereby causing the shell to fail in a brittle manner.en© 2021 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the International Conference on Applied Research and Engineering 2021. Notice : this is the author’s version of a work that was accepted for publication in Materials Today : Proceedings. Changes resulting from the publishing process, such as peer review, editing, corrections, structural formatting, and other quality control mechanisms may not be reflected in this document. A definitive version was subsequently published in Materials Today : Proceedings, vol. 56, pp. 2004-2009, doi : 10.1016/j.matpr.2021.11.344.MicrostructurePorosityHardnessFailureA357-T6 alloyEngineering, built environment and information technology articles SDG-08SDG-08: Decent work and economic growthEngineering, built environment and information technology articles SDG-09SDG-09: Industry, innovation and infrastructureEngineering, built environment and information technology articles SDG-12SDG-12: Responsible consumption and productionEngineering, built environment and information technology articles SDG-13SDG-13: Climate actionPostprint Article