Formation Of Adiabatic Shear Bands Research Articles

Numerical Investigation of the Damage Effect on the Evolution of Adiabatic Shear Banding and Its Transition to Fracture during High-Speed Blanking of 304 Stainless Steel Sheets.

This paper investigates numerically the effect of damage evolution on adiabatic shear banding (ASB) formation and its transition to fracture during high-speed blanking of 304 stainless steel sheets. A structural-thermal-damage-coupled finite element (FE) analysis is developed in LS-DYNA considering the modified Johnson-Cook thermo-viscoplastic model for both plasticity flow rule and damage law, while further, a temperature-dependent fracture criterion is implemented by introducing a critical temperature. The modeling approach is initially validated against experimental data regarding the fracture profile and ASB width. Next, FE simulations are conducted to examine the effect of strain rate and temperature dependence on damage law, while the effect of damage coupling is also evaluated, aiming to highlight the connection between thermal and damage softening and attribute them a specific role regarding ASB formation and transition to fracture. Also, the influence of dynamic recrystallization (DRX) softening is studied macroscopically, while further, a parametric analysis of the Taylor-Quinney coefficient is conducted to highlight the effect of plastic work-to-internal heat conversion efficiency on ASB formation. The results revealed that the implementation of damage coupling reacts to reduced ASB width and provides an S-shaped fracture profile, while it also decreases the peak force and results in an earlier fracture. Both findings are enhanced when accounting further for DRX softening and a higher value of the Taylor-Quinney coefficient. Finally, the simulations indicated that thermal softening precedes damage softening, showing that the temperature rise is responsible for ASB initiation, while instead, damage evolution drives ASB propagation and fracture.

Thermomechanical characterisation of a thermoplastic polymer and its short glass fibre reinforced composite: Influence of fibre, fibre orientation, strain rates and temperatures

Polycarbonate composites are widely used in products exposed to high strain rate deformation. This paper investigates the thermomechanical properties of polycarbonate and 20 wt% glass fibre reinforced polycarbonate to provide characterisation data and improved mechanistic understanding of the response to load, supported by Dynamic Mechanical Analysis and time–temperature superposition. Compressive behaviour is characterised from 0.001 to 5000 s−1 at room temperature and from −60 to 120 °C at 0.01 s−1; and a thermal imaging camera used to obtain temperature rise data. Quasi-static tensile experiments were also performed in different orientations relative to the injection flow direction. High-rate compression experiments are performed with X-ray imaging. As well as information about rate dependence of yield stresses and softening in the two materials, these data show how adiabatic shear band formation can cause significant softening in the composite. These data will enhance application of these polymers and facilitate development of advanced thermo-mechanical models.

A structural-thermal coupled modeling approach on the formation of adiabatic shear bands in steel sheet blanking process

Adiabatic shear banding reflects an unstable and dynamic plastic deformation mechanism occurring at high strain and strain rates which is strongly conjugated to fracture. Current work carries out a numerical study on the initiation and development of adiabatic shear bands (ASBs) in blanking process of AISI 4340 steel sheet. A structural-thermal coupled finite element analysis is developed in LS-DYNA software by implementing a thermo-viscoplastic flow rule for material plasticity and a damage criterion considering dynamic failure. The numerical simulations are focused on capturing ASB genesis through intense shear localization by evincing strain instability. Also, the evolution of ASB mechanism is investigated, aiming to contribute a stage-by-stage propagation and highlight its connection to dynamic failure. Further, the effect of ASB temperature and strain field on fracture is analysed, while the influence of strain/strain rate hardening and thermal softening on strain instability, peak force and the blanked surface is studied. The results revealed an S-shaped ASB due to severe shear localization and significant temperature increase, leading to dynamic recrystallization around punch-die corners and reacting to strain instability and dynamic. Finally, high magnitude thermal softening during ASB development resulted in earlier ASB generation and reduction of the peak blanking force, while further it decreased shear zone expansion and increased fractured length in the blanked surface.

A comparison of high strain rate response and adiabatic shear band formation in additively and traditionally manufactured Inconel 718

3D printing of Inconel 718 has been increasingly commercialized, as such research comparing the mechanical properties of additively manufactured (AM) and traditionally manufactured (TM) components in both quasi-static and high rate regimes should be conducted. Herein, the high strain rate material response, as well as the formation of adiabatic shear bands (ASBs) in AM and TM Inconel 718 are studied using a split Hopkinson pressure bar (SHPB) system. A top-hat cylindrical specimen geometry was used to convert the compressive load to shear and conduct high rate shear tests in the SHPB. The quasi-static and high rate stress-strain data reported herein indicates that TM components have at least a 70 MPa higher compressive yield strength. Interestingly, the AM specimens were more susceptible to ASB formation than their TM counterparts. The critical shear strain at which an ASB forms was higher for the TM specimens compared to the AM specimens. This was attributed to the TM material having a higher critical stress for dynamic recrystallization initiation, which is required to ASB formation. The microstructures of the shear zone in the top-hat specimens were examined using an optical microscope (OM), scanning electron microscope (SEM), and transmission electron microscope (TEM). Dynamic recrystallization was observed at the center of the shear affected zone (SAZ) using TEM from material lifted out from the ASB. Due to the plastic deformation in the shear region, the material strain hardens and therefore has a higher hardness than the bulk material. At the center of the shear region, a peak in nano-hardness of 585 HV was recorded on the ASB. The outcome of this research will lead to the prevention, containment, and control of shear instability in AM structures.

Dynamic mechanical performance of FeNiCoAl-based high-entropy alloy: Enhancement via microbands and martensitic transformation

The non-equiatomic FeNiCoAlTaB high-entropy alloy exhibits outstanding quasi-static mechanical properties. Here, we investigate the microstructural evolution and mechanical response of this alloy subjected to dynamic loading, which has not been done before. A novel strategy combining extensive microbanding and martensitic transformation improves the resistance to the plastic instability by deterring the formation of adiabatic shear bands, that only occur beyond a critical shear strain larger than 4. The aged alloy, with grain sizes up to 400 μm, exhibits a dynamic yield stress over 1300 MPa with good deformability in this regime. This investigation sheds light on potential strategies for the enhancement of dynamic mechanical properties of structural materials through the use of a stress-induced martensitic transformation.

Two-dimensional evolution of temperature and deformation fields during dynamic shear banding: In-situ experiments and modeling

Adiabatic shear band (ASB) is a significant failure mechanism observed in metals and alloys under impact loading. Though ASB formation has been widely assumed to be a one-dimensional thermo-mechanically-coupled instability problem, it is crucial to recognize that adiabatic shear banding is essentially a two-dimensional propagating event in space. However, it is challenging to perform in-situ characterization of temperature-deformation fields during ASB formation due to the extremely small spatial and temporal scales involved. To obtain the two-dimensional features of ASB evolution, a newly developed plane-array infrared imaging system and microspeckle-based digital image correlation (DIC) technique are synchronized with the Kolsky bar system. By incorporating interrupted tests, “quasi-synchronous” characterization of temperature-deformation-microstructure evolution during ASB formation in hat-shaped specimens of Ti–6Al–4V is achieved. A phase-field model incorporating energy-based shear banding criteria and independently calibrated model parameters is established to simulate the dynamic shear failure process, which is demonstrated to be able to well reproduce experimentally observed temperature and deformation evolution. Based on experimental characterization and simulation results, the two-dimensional features and thermo-mechanical aspects of ASB formation are presented. Energy dissipation of shear banding is estimated based on the measured temperature field, demonstrating good agreement with the calibrated values in the phase-field model. The “propagation” and “percolation” modes along the band are analyzed, which can be predicted by the introduction of a shear band process zone. The influences of thermal and microstructural softening on shear failure are also clarified through a comprehensive analysis of temperature and microstructure evolution.

A comparative study on dynamic deformation and ballistic impact response of Ti–4Al–2.5V–1.5Fe–0.25O and Ti–6Al–4V alloys

Titanium alloys are most suitable for lightweight armour applications due to their superior strength to weight ratio, and α+β Ti alloy Ti–6Al–4V is widely used in armour applications. One of the critical factors limiting the widespread use of Ti alloys in armour application is their high cost. Recently, Allegheny Technologies Incorporated introduced ATI-425® Ti alloy with the chemical composition of Ti–4Al-2.5V-1.5Fe-0.25O as a low-cost alternative to Ti–6Al–4V. Though ATI-425 Ti alloy is primarily intended for armour applications, only limited ballistic results are available in the open literature. In the present work, we compare the quasi-static, dynamic deformation, ballistic impact response and post-deformation microstructure of a low-cost α+β Ti alloy ATI-425 with that of Ti–6Al–4V alloy. Analysis of the results showed that both alloys showed similar yield strength values during quasi-static tension and compression tests, while ATI-425 Ti alloy showed higher tensile ductility, Charpy-V notch impact energy and dynamic flow stress than Ti-6Al-4V. The ATI-425 Ti alloy also exhibited slightly better ballistic performance measured in terms of V50 ballistic limit velocity. Detailed microstructural analysis on quasi-static and dynamic compression-tested samples showed mainly {101–2} tensile twins, whereas {101–2} and {112–1} tensile twins are observed in ballistic-tested samples of both the alloys. Activation of deformation twinning in ATI-425 Ti alloy with higher oxygen is attributed to lower Al content which enhances the twinning activity. Adiabatic shear band (ASB)-induced plugging mechanism is ascertained as the perforation mode in both alloys during the ballistic impact. Analysis of propensity to ASB formation indicated that Ti-6Al-4V has a slightly better resistance to ASB formation than ATI-425 Ti alloy. The improved ballistic performance of ATI-425 Ti alloy in comparison to Ti-6Al-4V is attributed to the higher dynamic flow stress, Charpy-V notch impact energy absorption, and moderate resistance to adiabatic shear band formation.

Susceptibility of adiabatic shear band formation in AZ31B magnesium alloy during high strain rate impact

Susceptibility of adiabatic shear band formation in AZ31B magnesium alloy during high strain rate impact

Effect of processing route on ballistic performance of Ti-6Al-4V armour plate

Titanium alloys are a key part of an armour designer’s toolset due to their high ballistic mass efficiency. However, titanium’s high cost has restricted its use in military land-based vehicles. In this study, the effect of different processing routes on the microstructure, texture, ballistic performance V50 and deformation modes of Ti-6Al-4V armour plate is investigated. Plates were fabricated via conventional hot rolling and the powder metallurgy techniques of HIP and FAST. The plate failure modes varied significantly with the microstructure while the formation of adiabatic shear bands seems to be influenced by crystallographic texture. The rolled plate exhibited the best performance due to a strong transverse-type texture perpendicular to the projectile direction.

Numerical studies of self-organization of shear bands in one and two dimensions

In the present manuscript we perform a numerical analysis of the self-organization processes of adiabatic shear bands formation in depleted uranium, aluminum alloy, and high-strength steel in one- and two-dimensional cases. Since the processes of shear bands formation are strongly nonlinear, three materials with significantly different parameters considered allow us to generalize obtained dependencies. For all materials, we investigate the evolution of stress, temperature and velocity fields from initial to final stage of localization. It is well known that localization processes occur during the high shear rate loads in the presence of initial microstructural defects in metallic materials. Starting with a random distribution of initial stress, which models microstructural defects, we obtained new dependencies for such significant parameters of the problem considered such as localization time and spacing between shear bands. The influence of initial plastic strain rate on these parameters was also studied. We obtain the linear dependence of localization time on initial strain rate and show that spatial dimension significantly influences on its value. Also, we introduce the method of shear bands selection during computations and present new statistical distributions for band spacing. We show that the interaction between shear bands significant influences on the spacing between them.

Investigation of the twin-induced adiabatic shear bands evolution in a Mg-Al-Mn alloy under ballistic impact

The formation and evolution of twin-induced adiabatic shear bands (ASBs) in a Mg-Al-Mn alloy under ballistic impact were investigated by analyzing the microstructures at three representative locations with different distances from the crater rim. Results show that localized shear deformation occurred at the twin boundaries, resulting in the formation of ASBs. The ASBs thicken at the expense of the deformation twins with increasing plastic deformation, forming ASBs which are mainly composed of subgrains, ultra-fine recrystallized grains and Mg17Al12 precipitates. The appearance of the twin-induced ASBs is mainly attributed to the twin-twin intersections caused by high strain rate deformation. The twin-twin intersections under high strain rate deformation lead to a different twinning activity in which the subsequent plastic deformation mainly occurs by shear deformation along the twin boundaries rather than thickening the twins. These results and analysis can shed new light on understanding the nucleation and evolution of ASBs in Mg alloys under dynamic loadings.

A comprehensive study on size-effect, plastic anisotropy and microformability of aluminum with varied alloy chemistry, crystallographic texture, and microstructure

Fabrication of microparts with large aspect-ratio and complex shapes remains a huge challenge for industries and microforming is a potential solution to manufacture such microparts. However, similarity in specimen-deformation and microstructural length scales during microforming results in size effect, leading to unpredictable plastic behavior and increased process scatter. One approach to counter size effect is by engineering suitable microstructure in the material. In the present work, three grades of Al (AA1070, AA5083, AA2014) with unique alloy chemistry and microstructural profile are processed by cryorolling (CR) to 95% thickness reduction. By imparting controlled postprocess annealing on the CR materials, three distinctive microstructures – (i) ultrafine grained (UFG) with average grain size around 1 μm, (ii) fine grained (FG) with average grain size near to 5 μm, and (iii) coarse grained (CG) with approximate average grain size of 20 μm are engineered. The influence of alloy chemistry, grain boundary engineering and crystallographic texture on microformability are studied. For pure Al (AA1070), the UFG and FG microstructures show superior microformability than the CG counterparts. The equiaxed UFG grains present in these microstructures mitigate the size effect abnormalities by increasing the number of grains in the deformation volume and uniformly distributing the complex microforming strain via grain boundary mediated plasticity. Their corresponding texture containing strong Copper mixed with scattered Cube elements promotes in-plane strain condition and high resistance to localized thinning. Also, the material shows near-zero planar anisotropy that leads to a homogenous in-plane strain distribution. Unlike pure Al, the UFG and FG Al alloys suffer from increased strain localization due to presence of solute clouds and nanoprecipitates. They influence strain-aging (Portevin–Le Chatelier effect), strain gradient hardening phenomenon, and shear propensity during failure of the Al alloys. A composite texture consisting of a combination of Brass, Dillamore, S, and β-fiber elements in the Al alloys is found to be detrimental to their microformability. The Dillamore texture is contributed by formation of adiabatic shear bands during deformation of Al alloys.

Influence of precipitate distributions on adiabatic shear band formation and flow behavior of heat-treated 7050 aluminum alloy

Influence of precipitate distributions on adiabatic shear band formation and flow behavior of heat-treated 7050 aluminum alloy

Effects of process parameters and loading direction on the impact strength of additively manufactured 18%Ni-M350 maraging steel under dynamic impact loading

The microstructural and damage evolution of 18%Ni M350 maraging steel fabricated by laser-based directed energy deposition (DED) process under dynamic impact loading are investigated in this study. The influence of additive manufacturing (AM) processing parameters, including laser power, powder feed rate, and energy area density (EAD) are discussed. The mechanical testing of the additively manufactured alloy was done using the split Hopkinson pressure bar (SHPB) system. The dynamic impact test was conducted using strain rates ranging from 100 to 4000 s−1. The test was conducted on cylindrical specimens (7 mm diameter and 8 mm long) with axes parallel to the build direction (Z-axis) and perpendicular (X- and Y-axis) to the build direction to evaluate the effects of loading directions on mechanical responses and microstructural evolution in the alloy under the impact loading conditions. The test results revealed that the materials processed using the lowest EAD parameters exhibit the greatest impact strength under dynamic impact loading for all directions. Specimens impacted along the build direction (Z-axis) exhibit a continuous drop in peak flow stress once the strain rates exceeded 2300 s−1 indicating the greatest susceptibility to thermal softening at high strain rates. Strain localization leading to the formation of adiabatic shear bands (ASB) was observed in some specimens. Cracks developed along the ASBs, while some AM-process-related defects, such as the lack-of-fusion, interacted with adiabatic shear bands, promoting cracking inside the shear bands. Despite possessing the highest impact strength, the materials produced by the lowest EAD parameters are the most susceptible to the development of adiabatic shear bands leading to cracking and fracture.

Investigation of initial metallurgical factors on the dynamic impact response and adiabatic shear bands formation of the 6061 Al alloy

The effect of multi-pass friction stir processing and initial base metal condition on the dynamic impact response of AA6061-T6 alloy at high strain rates was investigated in this study. The Split-Hopkinson Pressure Bar (SHPB) was used in dynamic experiments with strain rates ranging from 1600 to 4200/s. The results revealed that the base metal alloy's (BM) dynamic flow stress was comparable to all the friction stir processed AA6061-T6 (FSP'd) specimens as the strain rate and true strain increased. The general increase in stress response levels as strain rates and true strain increases can be attributed to strain hardening. The higher values of strain rate sensitivity in multi-pass FSP'd specimens are an indication that they are more ductile in comparison to the BM condition. The optical and electron backscattered diffraction (EBSD) analysis showed that adiabatic shear bands were formed by heterogeneous deformation. The EBSD analysis revealed that the FSP'd specimens showed more abnormal grain growth and dynamic recrystallized sites than BM. The substantial decrease in dynamic flow stress, and high strain rate sensitive values of multi-pass FSP'd specimens compared to BM for all the investigated strain rates attributed to softening effect by dynamic recrystallization (DRX), and the emergence of abnormal grain growth during friction stir process.

Microstructure evolution of adiabatic shear band in AZ31 alloy under dynamic compression

The formation of adiabatic shear band (ASB) and its damage behaviour in AZ31 alloy under high strain rate compression (2000 s−1) were investigated in this study by using a split Hopkinson pressure bar. Microstructure of the ASB was characterised by electron back-scattering diffraction and transmission electron microscopy, and the adiabatic shear damage behaviour was analysed through finite element simulation by LS-DYNA. The results show that the ASB and the surrounding microstructure form a gradient microstructure distribution, and the formation of ultra-fine grains in the ASB is due to rotational dynamic recrystallisation. The combination of work hardening and grain refinement in ASB leads to a high microhardness. Micro-voids grow in the ASB and eventually form macro-cracks, leading to material failure.

Dynamic compression deformation behavior of laser directed energy deposited α + β duplex titanium alloy with basket-weave morphology

Duplex titanium alloy with basket-weave morphology made by laser directed energy deposition (LDED) technique, has a bright application prospect in the armor protection field attributed to its excellent specific strength and bulletproof performance. In this research, the dynamic compressive deformation mechanisms of LDEDed TC11 titanium alloy under a strain rate of 3000/s are systematically investigated by investigating the dislocation slipping and twinning behavior. Meanwhile, this work gives explanations of the microstructure evolution of subsequent heterogeneous shear localization. The results indicate that TC11 alloy with basket-weave morphology possesses huge improvement in the average dynamic flow stress, uniform plastic strain, and impact absorption energy in contrast to that of titanium alloys with an equiaxed microstructure, which is known as the optimum prepared via traditional forming methods. The loading direction to α laths is largely responsible for slip modes manifestation under dynamic compression, which is illustrated in the unit triangle. When loading along < 0001 > at the vertex of the unit triangle, both basal slip and prismatic slip systems could not be motivated. When loading along directions within the unit triangle, either or both basal slip and prismatic slip systems could be activated, causing α lath twisting, rotation, or even refinement. Meanwhile, the Schmid factors reduction caused by α laths rotation results in the twinning, which will reduce the slip mean free path. During the heterogeneous shear localization, the adiabatic shear bands (ASB) formation finally leads to shear failure. The α laths within the transition zone in ASB are compressed to less than 200 nm in thickness. Ultrafine nanoscale equiaxed grains with few defects in the center zone of ASB are generated under dislocations pile-up and sub-grain rotation.

Adiabatic Shear Banding in Nickel and Nickel-Based Superalloys: A Review

This review paper discusses the formation and propagation of adiabatic shear bands in nickel-based superalloys. The formation of adiabatic shear bands (ASBs) is a unique dynamic phenomenon that typically precedes catastrophic, unpredicted failure in many metals under impact or ballistic loading. ASBs are thin regions that undergo substantial plastic shear strain and material softening due to the thermo-mechanical instability induced by the competitive work hardening and thermal softening processes. Dynamic recrystallization of the material’s microstructure in the shear region can occur and encourages shear localization and the formation of ASBs. Phase transformations are also often seen in ASBs of ferrous metals due to the elevated temperatures reached in the narrow shear region. ASBs ultimately lead to the local degradation of material properties within a narrow band wherein micro-voids can more easily nucleate and grow compared to the surrounding material. As the micro-voids grow, they will eventually coalesce leading to crack formation and eventual fracture. For elevated temperature applications, such as in the aerospace industry, nickel-based superalloys are used due to their high strength. Understanding the formation conditions of ASBs in nickel-based superalloys is also beneficial in extending the life of machining tools. The main goal of the review is to identify the formation mechanisms of ASBs, the microstructural evolutions associated with ASBs in nickel-based alloys, and their consequent effect on material properties. Under a shear strain rate of 80,000 s−1, the critical shear strain at which an ASB forms is between 2.2 and 3.2 for aged Inconel 718 and 4.5 for solution-treated Inconel 718. Shear band widths are reported to range between 2 and 65 microns for nickel-based superalloys. The shear bands widths are narrower in samples that are aged compared to samples in the annealed or solution treated condition.

High strain rate deformation behavior, texture and microstructural evolution, characterization of adiabatic shear bands, and constitutive models in electron beam melted Ti-6Al-4V under dynamic compression loadings

The results of an investigation on the influence of strain rate on the microstructural and texture evolution, adiabatic shear band characterization, and deformation mechanism of electron beam melted Ti-6Al-4V vertically built cylindrical rods are presented and discussed in this paper. Typical initial microstructure includes a mixture of α (aluminum-rich) and β phases (vanadium-rich) and grain boundary α along with the columnar prior β-grain boundaries. High strain rate compressive loadings were applied using a Split-Hopkinson pressure bar at the strain rates of 700 s−1 and 1650 s−1 at room temperature. By increasing the strain rate from 700 s−1 to 1650 s−1, the maximum stress and total strain in the alloy increased by 510 MPa and 141%, respectively. The higher dislocation density in the more severely deformed sample led to a more considerable amount of dislocation cells and consequent subgrains, high-angle grains, and piled-up dislocations. Intense shear strain localization leading to the adiabatic shear bands formation that occurred at higher strain rates. Texture investigations of the ASB region proposed that α→β phase transformation occurred within the ASB. Flow behavior prediction and experimental data revealed reasonable accordance, using the Gao-Zhang-Yan and the Chang-Asaro model.

Combined Tension-Shear Failure of Ductile Materials

Failure of ductile materials is usually expressed in terms of effective plastic strain. Ductile materials can fail by two different failure modes, shear failure and tensile failure. Under dynamic loading, shear failure has to do with shear localization and formation of adiabatic shear bands. In these bands plastic strain rate is very high, dissipative heating is extensive, and shear strength is lost. Shear localization starts at a certain value of effective plastic strain, when thermal softening overcomes strain hardening. Shear failure is therefore represented in terms of effective plastic strain. On the other hand, tensile failure comes about by void growth under tension. For voids in a tension field there is a threshold state of the remote field for which voids grow spontaneously (cavitation) and the material there fails. Cavitation depends on the remote field stress components and on the flow stress. In this way failure in tension is related to shear strength and to failure in shear. Here, we first evaluate the cavitation threshold for different remote field situations, using 2D numerical simulations with a hydrocode. We then use the results to compute examples of rate dependent tension-shear failure of a ductile material.