Micromechanical investigation of ductile failure in Al 5083-H116 via 3D unit cell modeling

Abstract

Ductile failure is governed by the evolution of micro-voids within a material. The micro-voids, which commonly initiate at second phase particles within metal alloys, grow and interact with each other until failure occurs. The evolution of the micro-voids, and therefore ductile failure, depends on many parameters (e.g., stress state, temperature, strain rate, void and particle volume fraction, etc.). In this study, the stress state dependence of the ductile failure of Al 5083-H116 is investigated by means of 3-D Finite Element (FE) periodic cell models. The cell models require only two pieces of information as inputs: (1) the initial particle volume fraction of the alloy and (2) the constitutive behavior of the matrix material. Based on this information, cell models are subjected to a given stress state, defined by the stress triaxiality and the Lode parameter. For each stress state, the cells are loaded in many loading orientations until failure. Material failure is assumed to occur in the weakest orientation, and so the orientation in which failure occurs first is considered as the critical orientation. The result is a description of material failure that is derived from basic principles and requires no fitting parameters. Subsequently, the results of the simulations are used to construct a homogenized material model, which is used in a component-scale FE model. The component-scale FE model is compared to experiments and is shown to over predict ductility. By excluding smaller nucleation events and load path non-proportionality, it is concluded that accuracy could be gained by including more information about the true microstructure in the model; emphasizing that its incorporation into micromechanical models is critical to developing quantitatively accurate physics-based ductile failure models.