Flow Stress Research Articles

Flow stress softening with Be content increase in the hot compressed Cu-Be alloy

The increase in beryllium content in Cu-Be alloys results in an unexpected reduction of hot-compressed flow stress at 780 °C and a strain rate of 1 s−1, accompanied by grain coarsening. This phenomenon can be primarily attributed to the rising volume fraction of the hard and brittle β phase with increasing beryllium content, which enhances dynamic recrystallization and consequently contributes more significantly to softening deformation.

Hot deformation behavior and dynamic recrystallization mechanism of GH2132 superalloy

In order to study the hot deformation and dynamic recrystallization behavior of annealed GH2132 superalloy, this paper conducted hot compression tests of GH2132 superalloy at different temperatures (950°C–1150°C) and different strain rates (0.01/s–10/s) using Thermocmaster Z thermal simulation testing machine, and made an in-depth analysis of recrystallization behavior via electron backscattered diffraction (EBSD). The results indicate that the flow stresses of GH2132 alloy first increase and then decrease at high temperature, among which the curves present a more obvious flow softening at 10/s. Continuous dynamic recrystallization (CDRX) is dominant at high temperature and low strain rate, while discontinuous dynamic recrystallization (DDRX) plays the major role at low temperature and high strain rate. The type of recrystallization has a significant impact on the formation and volume fraction of twinning. In addition, high-temperature constitutive model, hot processing map, and an unified dynamic recrystallization kinetic model of GH2132 superalloy were established. Thus, the optimal range of hot working parameters was obtained. The research results provide guidance for determining the hot working process window of GH2132 superalloy.

An extended mesoscaled M-K model for predicting discrete ultimate strains and evaluating the effect of normal stress on forming limits

Due to the size effect, the formability of metal sheets diminishes and the ultimate strain points exhibit a more discrete distribution. This poses a huge challenge to the process design and manufacture of microparts. This paper presents a modified mesoscopic scale forming limit model based on the M-K model. The model extends the forming limit curve (FLC) into forming limit bands to predict the discrete nature of the ultimate strain. In addition, a method for applying normal stresses to increase the forming limit of thin metal sheets is proposed. The effects of normal stresses on surface roughening and flow stresses in thin metal sheets were evaluated and quantified by uniaxial tensile experiments under normal stresses. The results show that the normal stress suppresses the increase of surface roughness and improves the work hardening rate. The effect of normal stresses on forming limits was obtained using a constructed model. The results show that the predictions of the proposed model are able to include almost all the ultimate strain points. The forming limit bands are more inclusive and safer than the single forming limit curve. In addition, the forming limits of thin plates under normal stresses are significantly increased, which is attributed to the suppression of surface roughening and the increase of strain hardening index. The forming limit bands proposed in this paper provide a more reliable form of forming limit assessment for thin metal plates. The proposed method of applying normal stresses provides a robust and inexpensive process route to address the challenge of poor formability of thin metal sheets.

Internal radiation effect on semiconductor β-Ga2O3 crystals grown by the VB Method and anisotropic thermal stress

Gallium oxide crystals are semitransparent semiconductors with good optical and electrical properties, which allow their use for several technological applications. During the growth process of β-Ga2O3 crystals, internal radiation plays a crucial role that affects the growth process and then the crystal quality. In this work, the effect of the melt and the crystal transparency on the vertical Bridgman growth of β-Ga2O3 oxide is thoroughly studied. Using a global 2D/3D finite element model, temperature, melt flow, melt-crystal interface, and three-dimensional anisotropic thermal stress are computed at different growth stages. At each stage, four cases are considered, namely, opaque melt and crystal, semi-transparent melt and opaque crystal, semitransparent crystal and opaque melt, and finally semitransparent melt and crystal. The role of internal radiation in each case at different growth stages is then highlighted separately and then coupled together. It was found that the melt-crystal interface is shifted from a convex shape at the early stage to a nearly plane and then to a concave shape at the last stage. The melt flow is then changed from two rolls pattern at the beginning to a single-roll structure at the last stage. Thermal stress of the as-grown ingot is decreased during the growth due to the decrease of temperature non-linearities. Internal radiation inside the crystal acts to increase the melt-crystal interface convexity at the early and middle stages of the growth process and leads to a decrease in its concavity at the final stage. However, the melt transparency leads to the opposite effects, i.e., it decreases the interface convexity at the early stage and increases the interface concavity at the final stage. As a result, for semitransparent crystal and melt, the interface is between the two previous cases. The calculated thermal stresses are found to be more affected by the transparency of the crystal than the melt as the absorption coefficient of β-Ga2O3 crystal is smaller than that of the melt. At all stages, the thermal stresses are found to be larger for the opaque case due to the increase of temperature non-linearities in the crystal. Large values are found at the bottom and the lower part of the periphery. Furthermore, internal radiation inside the melt plays a major role during the early growth stage due to the large liquid volume. It reduces the melt flow intensity close to the free surface where the shear stress is combined with the buoyant force and leads to the flattening of the interface decreasing then the radial temperature gradients, which leads to small attenuation of the thermal stress. At the final stage, the transparency of the melt plays the opposite role due to the increase of the interface concavity which leads to an increase in both of the temperature gradients and the thermal stress inside the crystal. Due to the crystal anisotropy, and especially to the large thermal expansion coefficient in the [010] direction, the 3D thermal stress values are found to be larger in this direction, especially in the bottom part of the ingot. Comparisons with available experimental and numerical works are provided in this paper.

Modeling the effects of initial grain size, martensitic transformation induced dynamic grain refinement, phases, and texture on strength of a high entropy alloy using crystal plasticity

Microstructurally flexible high entropy alloys (HEAs) can be tailored for strength via dual-phase strengthening mechanisms, which originate from the strain-induced phase transformation microstructural phenomena. One such alloy is a recently synthesized Fe42Mn28Co10Cr15Si5 (at%) HEA consisting of metastable gamma austenite (γ), stable epsilon martensite (ε), and stable sigma (σ) phases. In this work, a crystal plasticity homogenization incorporating a physically based phase transformation and hardening models is used to interpret and better understand the effects of strain induced phase transformation phenomena on the overall hardening response of the alloy. The transformation model is conceived based on the grain-scale stress sensitive motion of partial dislocations forming shear bands, while the hardening model is an extended Kocks-Mecking-type dislocation density-based formulation sensitive to grain size and shape. The deformation of constituent grains per phase in the alloy is modeled as a combination of anisotropic elasticity, crystallographic glide, and γ→ε phase transformation. Parameters of the hardening and transformation models within the homogenization are calibrated and validated on a suite of data including flow stress curves and phase fractions measured under compression, while the corresponding texture evolution data is used solely for verification. Good predictions of the model elucidate that the transformation induced dynamic Hall-Petch-type barrier effect is the primary origin of strain hardening along with the increase in the ε-phase fraction and dislocation density, while the individual strength of the phases gives rise to the overall strength. The modeling framework described in the present work is expected to be applicable to other HEA systems.

Chemical mapping of the surface interactome of PIEZO1 identifies CADM1 as a modulator of channel inactivation

The propeller-shaped blades of the PIEZO1 and PIEZO2 ion channels partition into the plasma membrane and respond to indentation or stretching of the lipid bilayer, thus converting mechanical forces into signals that can be interpreted by cells, in the form of calcium flux and changes in membrane potential. While PIEZO channels participate in diverse physiological processes, from sensing the shear stress of blood flow in the vasculature to detecting touch through mechanoreceptors in the skin, the molecular details that enable these mechanosensors to tune their responses over a vast dynamic range of forces remain largely uncharacterized. To survey the molecular landscape surrounding PIEZO channels at the cell surface, we employed a mass spectrometry-based proteomic approach to capture and identify extracellularly exposed proteins in the vicinity of PIEZO1. This PIEZO1-proximal interactome was enriched in surface proteins localized to cell junctions and signaling hubs within the plasma membrane. Functional screening of these interaction candidates by calcium imaging and electrophysiology in an overexpression system identified the adhesion molecule CADM1/SynCAM that slows the inactivation kinetics of PIEZO1 with little effect on PIEZO2. Conversely, we found that CADM1 knockdown accelerates inactivation of endogenous PIEZO1 in Neuro-2a cells. Systematic deletion of CADM1 domains indicates that the transmembrane region is critical for the observed effects on PIEZO1, suggesting that modulation of inactivation is mediated by interactions in or near the lipid bilayer.

High-temperature hot deformation behavior and processing map of Ti-22Al-25Nb alloy

The high-temperature deformation behavior of the Ti-22Al-25Nb alloy was investigated by conducting hot compression experiments. A constitutive equation predicting the flow behavior of the Ti-22Al-25Nb alloy was established by analyzing its stress–strain curves. The strain-compensated constitutive equation effectively predicted the flow stress of the alloy with a correlation coefficient of 0.992 between the measured and predicted values and an average absolute relative error of 6.548 %. A hot processing map was obtained based on a dynamic material model. It demonstrated that the optimal processing region corresponded to the deformation temperatures of 1273–1353 K and strain rates of 0.001–0.01 s−1. Using electron backscatter diffraction data, thermal deformation mechanisms were elucidated under different deformation conditions within the safe region. The obtained results revealed that under the low temperature (T ≤ 1323 K) and low strain rate (ε̇ ≤ 1 s−1) conditions, continuous dynamic recrystallization and dynamic recovery (DRV) were the main thermal deformation mechanisms. Under the medium-to-high temperature (T ≥ 1323 K) and low strain rate (ε̇ ≤ 1 s−1) conditions, the main thermal deformation mechanisms were discontinuous dynamic recrystallization and DRV. At high strain rates (ε̇ ≥ 1 s−1), the primary thermaldeformation mechanism was DRV. The occurrence of discontinuous yielding in the alloy at high strain rates was related to the proliferation of mobile dislocations at grain boundaries.

A molecular dynamics study on mechanical performance and deformation mechanisms in nanotwinned NiCo-based alloys with nano-precipitates under high temperatures

Abstract Molecular dynamics simulations are performed to investigate the mechanical behavior of nanotwinned NiCo-based alloys containing coherent L12 nano-precipitates at different temperatures, as well as the interactions between the dislocations and nano-precipitates within the nanotwins. The simulation results demonstrate that both the yield stress and flow stress in the nanotwinned NiCo-based alloys with nano-precipitates decrease as the temperature rises, because the higher temperatures lead to the generation of more defects during yielding and lower dislocation density during plastic deformation. Moreover, the coherent L12 phase exhibits excellent thermal stability, which enables the hinderance of dislocation motion at elevated temperatures via the wrapping and cutting mechanisms of dislocations. The synergistic effect of nanotwins and nano-precipitates results in more significant strengthening behavior in the nanotwinned NiCo-based alloys under high temperatures. In addition, the high-temperature mechanical behavior of nanotwinned NiCo-based alloys with nano-precipitates is sensitive to the size and volume fraction of the microstructures. These findings could be helpful for the design of nanotwins and nano-precipitates to improve the high-temperature mechanical properties of NiCo-based alloys.

Analytical temperature model for spindle speed selection in additive friction stir deposition

This paper describes a physics-based, analytical model for additive friction stir deposition (AFSD) spindle speed selection to achieve a desired deposition temperature. In the model, power input to the feedstock, which enables plastic flow and deposition, is related to the material temperature rise and subsequent flow stress reduction using Fourier’s conduction rate equation. Power input is modeled as frictional heating at the deposit-surface interface and adiabatic heating due to plastic deformation. The flow stress is predicted using the strain, strain rate, and temperature-dependent Johnson-Cook constitutive model for the selected feedstock alloy. Model predictions are compared to AFSD numerical simulation results available in the literature and experiments for aluminum alloys.

Effect of Trace Bismuth on Deformation Behavior of Ultrahigh-Purity Copper during Hot Compression

The effect of trace Bi impurities on the flow stress, microstructure evolution, and dynamic recrystallization (DRX) of the ultrahigh-purity copper was systematically investigated by a hot compression test at 600 °C. The results show that the peak stress of the ultrahigh-purity copper gradually decreases with increasing Bi content. Trace Bi impurities can refine the microstructure of ultrahigh-purity copper. However, the refinement effect of 50 wt ppm Bi is much more significant than that of 140 wt ppm Bi during the hot deformation. This effect is ascribed to the higher concentration of Bi at GBs, which induces severe GB cracks that reduces the driving force for the nucleation of DRX grains. In addition, the introduction of Bi inhibits the DRX of the ultrahigh-purity copper and transforms its DRX process from the discontinuous dynamic recrystallization (DDRX) to the coexistence of DDRX and continuous dynamic recrystallization (CDRX) mechanisms.

Characteristics of shear stress fluctuations in polymer solutions and their relation to turbulent structures in channel flows

In this study, the wall shear stress in the channel flow of polyacrylamide polymers was investigated through electrochemical experiments, and the effects of the polymer concentration were evaluated at different Reynolds numbers. The objective was to explore the relationship between the changes in the drag reduction and near-wall turbulence structure induced by the polymer. The experiments were conducted using polymer concentrations of 0, 20, 50, 100, and 150 ppm, and a drag reduction of approximately 23% was achieved at a bulk Reynolds number of Reb = 18 750. In the electrochemical method, the working electrode was arranged spanwise, and simultaneous measurements were performed for eight electrodes to discuss the scale of the near-wall low-speed streaks and burst events. A comprehensive analysis of the correlation of the wall shear stress in the streamwise direction and the cross-spectrum of two points in the spanwise direction revealed that large streamwise and spanwise scales of near-wall low-speed streaks were generated at high polymer concentrations. Furthermore, the results obtained using the variable interval time averaging technique indicated that polymer incorporation suppressed the wall shear stress fluctuations and weakened both the intensity and frequency of the bursting events.

A comparative study of hot tensile deformation behavior of 6016 aluminum alloy under LSTM neural network and Arrhenius model

Abstract The isothermal tensile test of 6016-T6 aluminum alloy was carried out on Gleeble-3500 at the temperature range of 400 °C–550 °C and the strain rate range of 0.01–10 s−1. The results show that the thermal deformation mechanism of 6016-T6 is dynamic recovery and dynamic recrystallization. In this paper, the phenomenological Arrhenius constitutive model and the data-driven WOA-LSTM constitutive model for predicting the hot tensile deformation behavior of 6016-T6 aluminum alloy were studied in contrast. The whale optimization algorithm was used to optimize the hyperparameters of LSTM neural network to improve the prediction accuracy of flow stress. The optimization results show that the optimal hidden layer node, maximum training period, initial learning rate and mini batch size of WOA-LSTM are 46, 260, 0.0248 and 16, respectively. In addition, the influence of the number of hidden layers on the results of the network was discussed. The appropriate hidden layer of the network was determined to be 2. The result show that the prediction accuracy of WOA-LSTM constitutive model is better than the Arrhenius constitutive model. The mean absolute error and correlation coefficient are 0.9348% and 0.99952, respectively. Among them, in this study, the Arrhenius constitutive model has low precision and only has high precision within a single temperature range.

Computational modeling of multi-track multi-layer laser directed energy deposition process

This study presents the development of a 3D fully coupled thermomechanical finite element model to evaluate the melt pool geometry, defects, and micro-hardness of multi-track multi-layer deposition in the powder feed laser-directed energy deposition (LDED) technique. Fabrication strategies can significantly affect the melt pool geometry and material behavior of the manufactured components. Understanding the effect of process parameters in a multi-track multi-layer LDED is important. Optimal process parameters are crucial for achieving high-quality deposition in terms of deposition geometry and integrity. The model can aid in mitigating issues such as inadequate inter-track or track-substrate fusion, porosity, cracks, and other defects. A multi-track multi-layer finite element model (FEM) can realistically predict melt pool evolution, mechanical properties, and defects in laser-LDED. This work focuses on the development of a fully coupled thermomechanical model for multi-track multi-layer deposition processes using ABAQUS®. The finite element framework employs Johnson-Cook’s flow stress model for constitutive behavior and the Koistein-Marburger equation for predicting hardness. Two tracks and two layers of SS316L powder are deposited on an SS304 substrate in finite element simulations and experiments. The model has been validated for the melt-pool depth in the substrate, deposition geometry, heat-affected zone, and hardness. It has been observed that there is a ∼10 % error in the prediction of melt pool geometry characterization and a ∼12 % error in hardness as compared to experimental results. The melt-pool width, depth, substrate dilution, and hardness have been characterized as a function of process parameters via simulations and experiments. The model is capable of predicting inter-track and interface defects. In addition, the effect of interlayer cooling on the melt-pool geometry and hardness has been studied.

Leveraging machine learning to minimize experimental trials and predict hot deformation behaviour in dual phase high entropy alloys

In recent time, high entropy alloys (HEAs) are widely used due to their wide design space and remarkable properties allowing a vast range of property variations with myriads of possible combinations of constituent elements. This research utilizes machine learning techniques, including Random Forest (RF), K-Nearest Neighbors (KNN), XGBoost (XGB), Decision Tree (DT), and Support Vector Regressor (SVR), to predict the flow stress behavior of the dual FCC phase CoCrCu1.2FeNi high entropy alloy (HEA) at new temperature and strain rates to reduce the experiments dependency. The RF and KNN models were identified as top performers, with R² values of 0.987 and 0.986, respectively. These models successfully predicted flow stresses, aligning closely with actual measurements. A new flow stress-strain curve was generated at new temperature of 1123K, demonstrating good performance metrics for RF and KNN. with R² values of 0.97 and 0.958 respectively. This approach has the potential to significantly reduce the need for extensive experimental work in determining the mechanical behaviour of HEA, offering substantial savings in time, cost, and energy, and marks a significant advancement in the development of such alloys.

A physically based constitutive model for 41CrS4 steel based on particle swarm optimization algorithm

Abstract Utilizing the Gleeble-3500 thermal simulation apparatus, a thermal compression assay was performed on 41CrS4 steel within the temperature range of 900 °C to 1200 °C, featuring a strain rate of 0.01 to 5 s−1, to derive its flow stress curve. The evaluation of the Arrhenius equation parameters was adeptly carried out by deploying a sophisticated particle swarm optimization algorithm. Through rigorous analysis, the correlation coefficient and the mean absolute deviation were calculated to quantify the alignment between the predictive accuracy of the developed model and the empirical data. The findings demonstrate the ability of the particle swarm optimization algorithm to significantly enhance the precision of the constitutive model. This augmented level of accuracy substantively increases the model’s utility and reliability for simulations of high-temperature material forming processes.

Inertia effect of deformation in amorphous solids: A dynamic mesoscale model

Shear transformation (ST), as the fundamental event of plastic deformation of amorphous solids, is commonly considered as transient in time and thus assumed to be an equilibrium process without inertia. Such an approximation however poses a major challenge when the deformation becomes non-equilibrium, e.g., under the dynamic and even shock loadings. To overcome the challenge, this paper proposes a dynamic mesoscale model for amorphous solids that connects microscopically inertial STs with macroscopically elastoplastic deformation. By defining two dimensionless parameters: strain increment and intrinsic Deborah number, the model predicts a phase diagram for describing the inertia effect on deformation of amorphous solids. It is found that with increasing strain rate or decreasing ST activation time, the significant inertia effect facilitates the activation and interaction of STs, resulting in the earlier yield of plasticity and lower steady-state flow stress. We also observe that the externally-applied shock wave can directly drive the activation of STs far below the global yield and then propagation along the wave-front. These behaviors are very different from shear banding in the quasi-static treatment without considering the inertia effect of STs. The present study highlights the non-equilibrium nature of plastic events, and increases the understanding of dynamic or shock deformation of amorphous solids at mesoscale.

A study on hot deformation behaviors and microstructures of 10 vol% SiCP/Al-Cu-Mg-Ag composite prepared by spray co-deposition and extrusion

Isothermal compression test is used to investigate the hot deformation behavior of spray co-deposited and extruded 10 vol% SiCP/Al-Cu-Mg-Ag composite. In this study, an accurate strain-compensated model based on Arrhenius constitutive equation is constructed with the corresponding R value of 0.9965 and AARE of 4.05%. The experimental results are in high agreement with the predicted flow stress. Hot deformation activation energy of the SiCP/Al composite (161.685 kJ/mol) is notably higher than that of Al-Cu-Mg-Ag alloy, which is attributed to the dislocations introduced by SiC reinforcement. The microstructure evolution of compressed specimens is characterized using EBSD and TEM. DRX, including CDRX and DDRX, is the main softening mechanism under the hot deformation conditions of high temperature, low strain rate and high strain. The softening mechanism transition from DRV to DRX is due to the subgrains consuming dislocations and then transforming into DRX grains. Comparing the microstructure under different hot deformation parameters, the recrystallization degree is significantly influenced by temperature, followed by strain rate and strain. In addition, the recrystallization process is impeded by the primary Al2Cu phases, T phases and SiC particles in the composite through hindering the migration of dislocations.

The effects of pre-existing dislocations on the mechanical properties of iron

In atomistic simulations, pre-existing dislocations have been reported to reduce the yield stress compared to the ideal crystals. However, the underlying physics behind yield stress reduction is still unrevealed, which hammers the design of advanced materials. Here, large-scale molecular dynamics simulations are carried out to investigate the influence of pre-existing dislocations on the mechanical properties of body-centered cubic Fe crystals with dislocation, twinning, and phase transformation-dominated deformation mechanisms. The results suggest that the overestimated yield stress of all the crystals is significantly reduced by increasing dislocation numbers and obtaining closer flow stress on the uniform plastic deformation stage. This reduction in yield stress can be attributed to the lower thermo-dynamical driving force required to activate existing dislocations in pre-existing dislocation crystals than that to nucleating new dislocations in ideal crystals. Furthermore, pre-existing dislocations inhibited the phase transformation-dominated deformation process, but the twinning/dislocation-dominated deformation process still exhibited its original deformation mechanism.

Unusual deformation mechanisms evoked by hetero-zone interaction in a heterostructured FCC high-entropy alloy

Understanding the synergistic mechanical effects of heterostructured materials remains challenging due to the complexities in the underlying deformation mechanisms, which are usually diverse, activated at different length scales and possibly interacting. Here, we unravel a deformation fundamental for heterostructures: in addition to the direct contribution on strength, hetero-zone interaction and the development of long-range internal stress could assist in evoking extra plastic mechanisms that are difficult to activate in their homogeneous counterparts. Specifically, the deformation of a heterostructure in Al0.1CoCrFeNi alloy, featuring nanostructured hard lamellae embedded in fine-grained soft matrix, is taken as an example for study. Drawing from experimental insights, the long-range internal stress buildup at elastoplastic transition stage due to intense dislocation pile-ups against hetero-zone boundary, which increases yield strength significantly, is theoretically analyzed. At the plastic stage, the high internal stress helps to activate phase transformation in the fine-grained zones, and the inter-zone constraint leads to form dispersed stable strain bands in the nanostructured zones. These extra mechanisms, together with enhanced deformation twinning, facilitate work hardening and coordinate the strain partitioning between zones, imparting improved ductility at high flow stress. These findings indicate a principle for heterostructural design: introducing strong hetero-zone interaction to enhance internal stress and thereby invoke new deformation mechanisms.

Biomechanics cerebral and carotid arteries: aneurysm development and atherosclerotic plaque detachment in the presence of combined pathologies

Today, the main cause of mortality in the world remains cardiovascular diseases. In this case, the combined pathology of the neck and head arteries, in which atherosclerosis affects the carotid arteries and there is a change in blood flow in the vertebral arteries or in the circle of Willis due to aplasia of the communicating artery, significantly increases the risk of aneurysms formation and their subsequent rupture. Assessing the risk of complications in this type of pathological condition may allow the physician to initiate timely preventive measures in specific clinical cases. The paper presents the results of modelling various variants of combined pathologies in the arteries of the neck and head. The segment under consideration includes sections of the common carotid, external and internal carotid arteries, as well as vessels of the circle of Willis and the basilar artery. The main idea of the study was to create a prognostic model to assess the risks of aneurysm formation in the circle of Willis and atherosclerotic plaque rupture in the carotid arteries. Such a system may be useful for physicians in routine practice when planning treatment tactics in patients with combined pathologies of the arterial channel. Based on the literature analysis, a number of pathologies of the cerebral and carotid arteries, most frequently occurring in various combinations, were identified: stenoses of the ICA (30 % and 70 %) and aplasia (absence) of one of the connecting arteries were considered from the point of view of geometrical features. In addition, the character of blood flow in the basilar artery, which can change its direction in steal-syndrome, was taken into account. Based on the analysis of blood flow and wall shear stress, two degrees of risk of aneurysm formation were distinguished. High risk corresponds to cases for which both of these values were statistically significantly different from the norm. Medium risk corresponds to cases for which only one of the values was statistically significantly different from the norm. For models containing atherosclerotic plaques, data on shear and normal stresses on the surfaces of atherosclerotic plaques were tabulated. The risk of plaque rupture on each side was determined for each case by analysing the result sets 11 combinations of pathological conditions with increased risk were indicated.