Non-uniform Plastic Deformation Research Articles

Evaluation of the errors of measuring residual stresses by the hole drilling method

A sample configuration with a specified distribution of residual stresses in depth was developed to elaborate modes for studying residual stresses using mechanical and physical methods. The sample formation technique is based on non-uniform plastic deformation of an aluminum beam of rectangular cross section according to the pure bending scheme. The control of the deformed state during loading was performed on the end surface of the sample by the field of normal deformations obtained using a digital image correlation system. The depth of the plastically deformed layer was 1.3 mm. The theoretical distribution of residual stresses obtained as a result of unloading of a plastically deformed sample was determined from the results of a numerical calculation of a finite element model, with allowance for the physical and mechanical characteristics, elastic-plastic hardening, as well as the deformation curve in true coordinates obtained as a result of uniaxial tension on elementary samples. A study of residual stresses inhomogeneous in depth was carried out by drilling holes in accordance with ASTM E837 on two opposite sides of the sample: the region of tension under loading and the area of compression, respectively. The control of the deformation response resulted from drilling was recorded using three-axis strain gauge rosettes. The results of the actual measurement of the longitudinal component of residual stresses were compared with their theoretical distribution obtained by a numerical method. The root-mean-square error in measuring residual stresses, relative to their theoretical distribution, for an aluminum alloy sample reaches 18.7 MPa. It should be noted that largest measurement errors were recorded at small depths, since they are characterized by small values of deformations comparable to the value of shot noise.

An approach for identifying the deformation-induced strain from tensile tests and x-ray diffraction measurements

ABSTRACT Non-uniform plastic deformation and phase transformation introduce residual stress (RS) in a material. The present study focuses on the influence of tensile strain on RS development in 304L austenitic stainless steel, wherein strain-induced martensite (SIM) transformation influences deformation behaviour. Room temperature tensile tests were interrupted at various tensile strains between the material yield and ultimate tensile strength at 5.21 × 10−4 and 1.3 × 10−2 s−1 strain rates. Microstructural characterisation of as-received and deformed samples by electron backscatter diffraction provides evidence of SIM formation and shear bands. Analysis of tensile flow and work hardening behaviour is discussed in correlation to the microstructural and dislocation density variations. In addition, RS in the austenite and martensite phases was measured using the x-ray diffraction method, and the RS balance that occurs between the longitudinal and transverse components and the two phases after tensile deformation is presented. It is shown that a combined analysis of RS and x-ray diffraction peak width could be utilised to find the deformation level in tensile fractured, press brake bent, and roll bent samples.

Research on microstructure and mechanical properties of TC4/304 clad plates by asymmetric rolling with local strong stress

In order to solve the problems of complex traditional preparation process and low bonding strength of titanium/steel clad plates, TC4/304 clad plates were prepared by asymmetric rolling with local strong stress (ARLSS), the effect of rolling temperature on the interface bonding of clad plates was studied. The two-dimensional simulation model of TC4/304 clad plates rolling was established by finite element method, and its accuracy was verified by experiments. The experimental results show that the interfacial bonding strength of the clad plates increased with the increasing temperature, but when the temperature reached 950 °C, the brittle intermetallic compounds (IMCs) formed extremely fast, which greatly weakens the bonding strength. The clad plates showed the best bonding strength at 900 °C. After corrugated roll bonding (CRB) (33 % reduction ratio), the bonding strength at the peak was lower than that at the trough. After FRB (46 % reduction ratio), the interface bonding strength was slightly improved. The final peak bonding strength reached 519 MPa, and the trough bonding strength was 527 MPa. The improvement of bonding strength mainly came from the improvement of TC4 matrix strength. The finite element simulation results showed that multiple cross shear zone in the deformation zone of the CRB stage were beneficial to the bonding of dissimilar metals. While the deformation of the clad plates material in the FRB stage was consistent, which effectively avoided the cracking of the bonded area and further improved the bonding strength. Therefore, the strong non-uniform plastic deformation of ARLSS process had a significant effect on the deformation coordination of dissimilar metals and the quality improvement of clad plates.

Study on the Residual Strength of Nonlinear Fatigue-Damaged Pipeline Structures

The heat alternation and bending during the service process of the pipeline structure are the key issues affecting its residual strength. The nonuniform plastic deformation of its cross-section causes nonlinear damage to the structure, which makes it difficult to calculate the residual strength of the overall structure. This study proposed a novel variable-strength material damage model with damage accumulation, which achieved the coupling analysis of structural damage and material fatigue residual strength, making the structural strength of nonlinear damage cross-section computable. Based on this, a theoretical ultimate load model for nonlinear damage cross-section and a finite element analysis model for dynamic material strength with damage accumulation were established. The analysis was conducted on the repeated banding damage to coiled tubing. The results showed that the residual yield strength of nonlinear damaged coiled tubing showed a trend of first rapid decrease and then slow decrease with damage accumulation, and the tensile displacement showed an increasing trend with damage accumulation. The ultimate internal pressure strength of nonlinear damaged structures showed a similar downward trend to the yield strength. The nonlinear damage coupling analysis model proposed in this study has significant practical engineering application value.

Additional effect on the deformation zone during plastic metal flow

In the article, on the basis of previously conducted theoretical and experimental studies, a phys-ical model of the process of additional impact on the basis of non-uniform plastic deformation is developed and investigated. On the basis of the physical model, a mathematical model of the additional impact is developed, the generalizing factor of which in the case of asymmetric de-formation is the external moment from the side lines.

The Mechanism of Deformation Compatibility of TA2/Q345 Laminated Metal in Dynamic Testing with Split-Hopkinson Pressure Bar.

The laminated metal materials are widely used in military, automobile and aerospace industries, but their dynamic response mechanical behavior needs to be further clarified, especially for materials with joint interface paralleling to the loading direction. The mechanical properties of TA2/Q345 (Titanium/Steel) laminated metal of this structure were studied by using the split Hopkinson pressure bar (SHPB). To shed light on the stress-state of a laminated metal with parallel structure, the relative non-uniformity of internal stress R(t) was analyzed. The mechanism of deformation compatibility of welding interface was discussed in detail. The current experiments demonstrate that in the strain rate range of 931-2250 s-1, the discrepancies of the internal stress in specimens are less than 5%, so the stress-state equilibrium hypothesis is satisfied during the effective loading time. Therefore, it is reasonable to believe that all stress-strain responses of the material are valid and reliable. Furthermore, the four deformation stages, i.e., the elastic stage, the plastic modulus compatible deformation stage, uniform plastic deformation stage and non-uniform plastic deformation stage, of the laminated metal with parallel structure were firstly proposed under the modulating action of the welding interface. The deformation stages are helpful for better utilization of laminated materials.

Role of microstructural stability and superdislocation shearing on creep behavior of two low-cost Ni-based single crystal superalloys at 1100 °C/130 MPa

In order to satisfy the pursuit of advanced aeroengines with low cost and high temperature capacity, the novel Re-free and Re-low single crystal superalloys were designed based on the strategy of Re-reduction. The creep lives of the two experimental alloys at 1100 °C/130 MPa both exceed that of René N5, and the Re-low alloy displays better creep performance and microstructural stability than the Re-free alloy. At the end of steady creep stage, due to the strong hindrance of interfacial dislocation networks, only a few superdislocations with Burgers vectors a<110> and a<001> enter into γ′ phase in the Re-low alloy. In the Re-free alloy, non-uniform plastic deformation leads to the severe γ/γ′ topological inversion, resulting in high-density a<110> superdislocation arrays in γ′ rafts, which can further react to form superdislocation networks. Moreover, the increasing μ phase precipitated with the prolonging creep time also promotes earlier failure of the Re-free alloy. In summary, the Re addition can improve creep resistance through reducing rafting rate of γ′ particles, stabilizing interfacial dislocation networks and increasing the APB energy of ordered γ′ phase. The above results provide favorable experimental basis for the development of low-cost single crystal superalloys.

Initiation and growth of edge cracks after shear cutting of dual-phase steel

Dual-phase steels suffer from low edge ductility, which limits their formability. In this study, an in-plane bending test is used to investigate the initiation and evolution of edge cracks. The edges of samples were prepared by shear cutting and afterwards further deformed by the in-plane bending test. Void distribution and non-uniform plastic deformation were explored with the help of scanning electron microscope (SEM) and electron backscatter diffraction (EBSD) analysis and microhardness measurement in different regions of the material edge. The extent of micro-cracks was revealed by microcomputed tomography (µCT) scan. The result shows that the blanking process creates inhomogeneous void distribution in the thickness direction. As the deformation increases during the subsequent in-plane bending test, the micro-cracks initiate at the burr region and grow towards the rollover region. Once they entirely pass the thickness of the material, they grow further, away from the edge. High roughness, plastic deformation, and void volume fraction were observed at the burr region, triggering crack initiation. The in-plane bending test successfully distinguished the dominant mechanism behind edge cracking.

Non-uniform plastic deformation in additive friction stir deposited Ti-6Al-4V

Ti-6Al-4V (Ti-64) material deposited by additive friction stir deposition (AFSD) on a rolled Ti-64 base plate was evaluated. Extracted tensile coupons containing both base plate and AFSD regions showed different stress–strain responses in uniaxial tensile testing with digital image correlation. These differences were rationalized based on microstructure gradients observed by optical microscopy and spatially resolved laboratory X-ray powder diffraction (PXRD). The AFSD regions show characteristic basket weave α-Ti microstructure within the 25–50 μm prior β grains. The base plate shows a globular α+β microstructure typical of the rolled and annealed state. In one sample, plastic strain concentration occurred in the AFSD region where diffraction analysis indicates the 〈hki0〉α-Ti directions were preferentially loaded. In the second sample, strain concentration occurred in the rolled base plate, but the textured domains were smaller than the area probed by PXRD. The control of prior β microstructure using targeted deposition temperature and shear rate and axial stress will be critical to achieving rapid volumetric control for targeted final properties using AFSD with titanium alloys.

Study of microstructure and mechanical properties of 17-4 PH stainless steel produced via Binder Jetting

ABSTRACT The microstructure and mechanical properties of 17-4 stainless steel produced by Binder Jetting (BJT) and heat treated according to the standard conditions for the 17-4 PH steel (H900 and H1100) were investigated. The sintered relative density is 97.8% with a slightly anisotropic shrinkage. Tensile strength and elongation are above the minimum required for the wrought steel and comparable to those of the same material manufactured by Metal Injection Molding. They are also better than those reported in the literature for the 17-4 PH stainless steel manufactured by BJT. Tensile elongation at fracture is anisotropic, highlighting a significant dependence of the non-uniform plastic deformation on the direction.

Modeling on displacement response and damage mechanism of contact interface during installation for composites sleeved interference joint

Interference-fit has remarkable advantages in improving the load-bearing performance of the structure, but the interface damage caused by interference installation becomes a weakness in the reliable application of composite joints. Therefore, a reliable and effective physically-based numerical model to reveal the displacement response and damage mechanism of contact interface during installation for composites sleeved interference joint was developed by combining the physically-based LaRC05 criterion and the energy-based linear softening law in this paper. The Partition Golden Section Search algorithm was employed to balance the accuracy of damage prediction and computational efficiency. The interference installation simulations with different geometric parameters were carried out and validated by experiments. Results show that the larger the bolt-sleeve interference-fit percentage, the more severe the non-uniform plastic deformation of the sleeve in the installation. Increasing the sleeve thickness can improve the uniformity of radial displacement distribution of the sleeve and alleviate the interface damage, but it cannot eliminate the connection gap. Choosing the appropriate sleeved fastener with taper can effectively avoid the aforementioned gap, improving the uniformity of displacement distribution and even reducing the interface damage.

An improved springback model considering the transverse stress in microforming

To satisfy the higher accuracy requirement in the microforming of thin-walled structures, the springback behavior under miniaturizing dimensions need to be accurately predicted and controlled. However, as the feature size approaches the thickness in microforming, many assumptions in conventional springback model for macroforming are not valid making these models can hardly provide effective springback analysis in microforming. In the present work, the applicability of a springback analytical framework of conventional stretch-bending was first explored via bending tests of 0.1 mm-thick SS316L sheets under different holding conditions with a punch radius from 3 to 5 mm which is much greater than the thickness. The analytical springback angle results agree with the experimental ones with the maximum error of 4.2% for different punch radii, grain sizes and stretching forces conditions, indicating the correctness of the model. The model was further verified in the microforming of parallel channels with a fillet radius of 0.15 mm. Finite element simulations were conducted to obtain the stretching loads for each channel. However, a significant underestimation of the channel height after springback for over 15% was found especially for the middle channel. The transverse stress is revealed to be no longer neglectable due to the strong stretching load and the small die radius during the microforming of parallel channels, which substantially contributes to yielding, hardening and thickness reduction in the stretch-bending area. In addition, the uneven stretching also affects the springback angle and channel height, which is caused by the nonuniform plastic deformation of the adjacent channels. By incorporating the effects of the transverse stress and the non-uniform stretching loads, an improved springback model was developed for microforming of parallel channels in this work. The shift distance of the neutral plane is better estimated by the improved model than by the conventional one. The predictive heights by the improved model are also revealed to agree with the experimental ones during the microforming of parallel channels with a maximum error of less than 5%.

Low Cycle Fatigue Behavior of Plastically Pre-Strained HSLA S355MC and S460MC Steels.

Cold roll forming used in the manufacturing of lightweight steel profiles for racking storage systems is associated with localized, non-uniform plastic deformations in the corner sections of the profiles, which act as fatigue damage initiation sites. In order to obtain a clearer insight on the role of existing plastic deformation on material fatigue performance, the effect of plastic pre-straining on the low cycle fatigue behavior of S355MC and S460MC steels was investigated. The steels were plastically deformed at different pre-strain levels under tension, and subsequently subjected to cyclic strain-controlled testing. Plastic pre-straining was found to increase cyclic yield strength, decrease ductility, and induce cyclic softening, which, in S460MC, degrades fatigue resistance compared to the unstrained material. In unstrained conditions, the materials present a cyclic softening to hardening transition with increasing plastic strain amplitude, which in S355MC occurs at lower strain amplitudes and degrades its fatigue resistance with regard to the pre-strained material. Pre-straining also leads to a reduction in transition life from low to high cycle fatigue. SEM fractography, performed following the onset of crack initiation, revealed that plastic pre-straining reduces the fatigue fracture section as well as striation spacing, predominantly in the S355MC steel.

Effect of volume fractions of gradient transition layer on mechanical behaviors of nanotwinned Cu

Heterogeneous nanostructured (HNS) materials, such as gradient and laminated nanostructured metals, possess superior mechanical properties with respect to their homogeneous counterparts. The additional strengthening mechanism of HNS is mainly attributed to the non-uniform plastic deformation induced by gradient transition layers (GTLs) between components. Here, we designed three gradient nanotwinned (GNT) Cu samples with different volume fractions of GTLs (fg) of 10%, 50% and 100% while the rule-of-mixture strength and overall structural gradient are constant to quantitatively reveal its effect on the extra strengthening behaviors. As fg increases, the yield strength is improved and the elastic to plastic stage is prolonged at small strain. Moreover, larger fg suppresses the strain localization and reduces nucleation of cracks at larger strain, accompanied by more widely distributed geometrically necessary dislocations (GNDs) and more bundles of concentrated dislocations (BCDs), thus improving the elongation. Stress partitioning analysis and numerical simulations show that the more widely-distributed GNDs at larger fg result in higher overall back stresses but hardly affect effective stresses, indicative of the origin of the improved strengthening. Such GND-distribution dominated strengthening mechanism paves a fundamental way for developing higher-performance HNS materials.

Shear banding-induced 〈c+a〉 slip enables unprecedented strength-ductility combination of laminated metallic composites

Shear bands in metallic materials have been reported to be catastrophic because they normally lead to non-uniform plastic deformation. Ductility of laminated metallic composites deteriorates with increasing processing strain, particularly for those having hexagonal-close-packed (hcp) constituents due to inadequate slip systems and consequently prominent shear banding. Here, we propose a design strategy that counterintuitively tolerates the bands with localized strains, i.e. the shear banded laminar (SBL) structure, which promotes 〈c+a〉 dislocation activation in hcp metals and renders unprecedented strength-ductility combination in hcp-metal-based composites fabricated by accumulative roll bonding (ARB). The SBL structure is characterized with one soft hcp metal constrained by adjacent hard metal in which dislocations have been accumulated near the bimetal interfaces. High-energy X-ray diffraction astonishingly reveals that more than 90% of dislocations are non-basal in Ti layers of the SBL Ti/Nb composite processed by eight ARB cycles. Moreover, 〈c+a〉 dislocations occupy a high fraction of ∼30%, promoting further 〈c+a〉 cross slip. The unique stress field tailored by both shear banding and heterophase interface-mediated deformation accommodation triggers important 〈c+a〉 slip. This SBL design is of significance for developing hcp-based laminates and other heterostructured materials with high performances.

Modeling size effects in microwire torsion: A comparison between a Lagrange multiplier-based and a [formula omitted] gradient crystal plasticity model

The size-dependent response of metallic microwires under monotonic and cyclic torsion is modeled taking a reduced-order strain gradient crystal plasticity approach involving a single scalar-valued micromorphic variable. It is compared with the response predicted by the CurlFp model proposed in Kaiser and Menzel (2019a), which is based on the complete dislocation density tensor. It is shown that, in cyclic non-uniform plastic deformation processes, the gradient of the scalar-valued internal variable in the reduced-order model predicts isotropic hardening in contrast to kinematic-type hardening produced by the CurlFp model due to a dislocation-induced back-stress component. The arising size effect in the monotonic torsion tests is described by the normalized torque T/R3 as a function of the ratio of the microwire radius R and the characteristic length scale ℓ. In the size-dependent domain, characterized by an inflection point on the corresponding curve, the scaling law T/R3∼(R/ℓ)n can be identified, and explicit relations are found for the power n. The relative evolution of Statistically Stored Dislocation (SSD) and Geometrically Necessary Dislocation (GND) densities during torsion is described in detail.

Thermodynamic theory of dislocation/grain boundary interaction

The thermodynamic theory of dislocation/grain boundary interaction, including dislocation pileup against, absorption by, and transfer through the grain boundary, is developed for non-uniform plastic deformations in polycrystals. The case study is carried out on the boundary conditions affecting work hardening of a bicrystal subjected to plane constrained shear for three types of grain boundaries: (i) impermeable hard grain boundary, (ii) grain boundary that allows dislocation transfer without absorption, and (iii) grain boundary that absorbs dislocations and allows them to pass later.

Influence of Change in the Apparent Contact Area, Temperature and Vacuum on Tribo Response of Al6061 and EN8 Pair

Objective: Aluminium and its alloys components are used in aero and space industries where in many cases trioboloading prevails. In space application, in addition to triboloading, the components should also perform in the absence of atmosphere. In the present investigation, attempted has been made to simulate the field conditions in the laboratory by sliding Al6061 alloy pin of different diameters in a vacuum at different temperatures using a vertically configured pin-on-disc test rig. Method: The pin diameters were 2, 4, and 6mm and the testing temperatures were 373, 473, and 573K. The normal contact pressure was 0.625MPa and the sliding speed was 0.5ms-1 and both were constant throughout the experiment. The coefficient of friction was monitored using a PC and the worn pin surface was studied in scanning-electronmicroscope. Findings: The result showed that the coefficient of friction at sliding temperatures 373 and 473K was found to be dependent on apparent contact area i.e., pin diameters 2, 4, and 6mm. The coefficient of friction was found to be 3.27 and 2.69 for pin diameter 2mm at temperature 373 and 473K whereas the coefficient of friction was of the range 1.36 to 0.33 for the pin of diameter 4 and 6mm. The scanning-electron-microscopic study revealed uniform plastic deformation for pin diameter of 2mm and non-uniform plastic deformation accompanied with abrasion extrusion phenomenon for the pin of diameters 4 and 6mm. The coefficient of friction at sliding temperature 573K was found to be insensitive to the apparent contact area. The coefficient of friction was in the range of 1.24 to 2.30. The SEM study revealed a large scale of non-uniform plastic deformation accompanied by abrasion, tearing of ridges, extrusion of both ridges, and entrapped wear debris. Novelty: It is a generic study for understanding the response of aluminium for tribo loading which. Keywords: Pin on Disc (POD); Scanning Electron Microscope (SEM); High Temperature; Vacuum; Coefficient of Friction; Al6061 Aluminium Alloy 1

Influence of Plastic Deformation on Microstructural Evolution of 100Cr6 Bearing Ring in Hot Ring Rolling.

The hot ring rolling technology as the crucial procedure for the manufacture of bearing rings plays an important role in determining the final microstructure of bearing rings. In this work, the influence of the hot ring rolling process on the microstructural evolution of 100Cr6 bearing rings was investigated using a three-dimensional (3D) numerical model and microstructural characterization. It was found that the significant microstructural refinement occurs at the different regions of the rings. However, owing to the non-uniform plastic deformation of hot rolling, the refinement rate of grain size and decrease of pearlite lamellar spacing (PLS) also showed uniformity at different regions of the rings. Furthermore, the degree of grain refinement had been limited with the increase of rolling reduction. Due to the refined grain size and decreased PLS, the Vickers hardness increased with the increase of rolling reduction. Moreover, the Vickers hardness from the outer surface to the inner surface of the ring is asymmetrical u-shaped, which had the law of lower hardness in the center area and higher hardness on the surface.

A closed-form analytical solution for residual stresses due to the bending of bilayer sheets

Bending is a conventional manufacturing process of sheet forming. This process induces reasonable residual stress through the thickness. Prediction of this residual stress profile is more difficult in bilayer sheet bending due to different material properties and thickness of layers. In this article, the residual stress distribution will be derived analytically for a bilayer sheet. The induced stress profile due to loading and released stress after unloading has been derived by integration along with the thickness. Also, the neutral axis movement due to non-uniform plastic deformation has been involved in the solution. The stress distribution has been derived analytically for elastic–perfect plastic, elastic–linear plastic and elastic–power law hardening material behavior. The results obtained from the proposed equation are compared by a finite element analysis. The finite element analysis contains bending a bilayer sheet to a specified curvature radius by a three-roll bending process. Comparing the results of the analytical solution and finite element analysis shows good agreement. The location of the neutral axis and the maximum of residual stresses in the thickness have been predicted very well with the proposed equation.