Abstract
A dislocation density based constitutive model has been developed and implemented into a crystal plasticity quasi-static finite element framework. This approach captures the evolution of dislocations and grain fragmentation at the bonding interface when boundary conditions pertaining to the Ultrasonic Consolidation process (UC) are prescribed. The model is initially calibrated using experimental data from published refereed literature for simple shear deformation of a single crystal pure aluminum and uniaxial tension of a polycrystalline Aluminum 3003-H18 alloy. The model has then been extended to predict the results of an Al 3003- H18 alloy undergoing UC. Good agreement between the experimental and simulated results has been observed for the evolution of linear weld density and embrittlement due to grain substructure evolution. For computational time efficiencies, a novel time homogenisation approach has been followed which significantly reduces the computational overhead.
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