Strain Rate Research Articles

Ultrasonic and conventional fatigue behavior, strain rate sensitivity, and structural design methods for wrought and cold spray Al-6061

Cold spray is an additive manufacturing process that accelerates powder particles to supersonic speeds to create repairs and bulk depositions with fine-grained microstructures, high density, and good mechanical properties. Fatigue property measurement for these novel materials is critical for their use in safety-critical components, which can be accelerated with the use of ultrasonic fatigue testing. In this work, ultrasonic (20 kHz) and conventional (20 Hz) fatigue studies were conducted on as-sprayed bulk Al-6061 and conventional wrought Al-6061-T6. Complementary fatigue studies of surface preparation (surface finish and residual stress) and fatigue specimen geometry (round versus flat), as well as hole-drilling residual stress measurements, were undertaken to minimize the influence of these confounding variables. Cold spray Al-6061 exhibits fatigue frequency sensitivity, whereas the wrought material does not. Tensile testing at varied strain rates indicates that a portion of the fatigue frequency effect can be attributed to strain rate sensitivity. Fractographic studies show that crack initiation occurs from unbonded powder particles at the surface at high stress amplitude, and transitions sub-surface at lower stress amplitude. The results of these studies were used to create frequency-corrective models of S-N data and Kitagawa-Takahashi diagrams that can be used to design for fatigue crack initiation and growth resistance.

Mechanical-electric response characteristics of 1–3 connectivity pattern cement-based piezoelectric composite sensors with varying functional phase parameters under impact loading

In this study, 1–3 connectivity pattern cement-based piezoelectric composites (CPCs) and cement-based piezoelectric composite sensors (CPCSs) with varying functional phase parameters were developed. The essential properties of the CPC specimens were systematically characterized. Additionally, the mechanical-electric response characteristics of the CPCS specimens under impact loading were examined using the split Hopkinson pressure bar (SHPB) technique. The results indicate that the piezoelectric constant (d33) of the CPC specimens increases with higher functional phase volume ratios and greater composite thickness. Under impact loading, both stress and electric displacement showed similar response patterns, demonstrating a strong force-electric coupling. Furthermore, within the experimental range, the electric displacement of the CPCS specimens increased with strain rate, indicating their potential for real-time monitoring of dynamic responses under varying impact conditions.

Analysis of grain structure, precipitation and hardness heterogeneities, supported by a thermal model, for an aluminium alloy 7075 deposited by solid-state multi-layer friction surfacing

Thermomechanical cycles during multi-layer friction surfacing (MLFS) cause microstructural and mechanical heterogeneities in the deposited high-strength Al alloy, 7075. The thermal profile and heat accumulation were investigated in this study using a multilayer numerical thermal model of the MLFS process; additionally, these variables were linked to experimentally observed microstructural heterogeneities. Compared with the feedstock, grain sizes decreased by 55–80%. The mean grain size at the bottom and top areas of a given layer was finer than that in the middle of the layer because of the enhanced recrystallisation, which resulted from the friction and shear deformation experienced by the deposited material. The differences in the thermal cycle and plastic strain rate of the bottom and top areas along the layers resulted in a gradual increase in the grain size at the bottom of each layer and a reduction in the grain size at the top of each layer. The grain growth and continuous dynamic recrystallisation mechanisms are governed by the temperature and strain rate, those mechanisms determine the intra- and inter- layer grain sizes. The accumulated heat, owing to subsequent experimental deposition, resulted in excessive growth of the precipitates in the bottom layers. The strengthening of the solid-solution and Guinier-Preston zones significantly increased the microhardness of the top layer. Post-deposition T6 heat treatments confirmed the restoration of a uniform distribution of microhardness.

Electromagnetic radiation of granite under dynamic compression

To elucidate the characteristics and mechanism of electromagnetic radiation in granite under impact loading, based on the quasi-static compression tests, this paper conducts dynamic compression experiments on granite using Hopkinson pressure bar and one-stage light-gas gun as loading methods. Combined with experimental and theoretical analyses, the relationship between mechanical and electromagnetic responses under impact loads of different intensities, and the time-domain signals of electromagnetic radiation generated by a single crack under different strain rates are studied. The intensity and frequency of electromagnetic radiation increase with the increasing compressive strain rate. According to the thermal activation theory, it reveals the microscopic mechanism of the transition from intergranular microcracks to transgranular microcracks in terms of strain sensitivity. It also serves as the physical basis for the increase in electromagnetic radiation intensity amplitude and frequency with increasing compressive strain rate. Transgranular microcracks are the primary cause of electromagnetic radiation generated by fractures.

A new nanoindentation approach for determining both indentation size effect and continuous apparent activation volume during loading of nanocrystalline Ni and Ni-20 wt.% Fe alloy

A new nanoindentation approach is developed in this study to determine both indentation size effect (ISE) and continuous apparent activation volume () during loading of nanocrystalline nickel (NC Ni) and nanocrystalline nickel-20 wt.% iron alloy (NC Ni-Fe alloy). This approach involves conducting nanoindentation tests under loading modes controlled by both constant strain rate (CSR) and constant loading rate (CLR). Firstly, a new empirical expression for the parameter in the modified Nix-Gao model is established to study the strain rate dependence of the ISEs created in the CSR and CLR tests. Then, continuous data of each individual sample (indentation) during loading are obtained in the CLR test through the alternative use of continuous stiffness measurement technique. The stress dependence of is analyzed based on Duhamel et al.’s model, which considers the role of vacancies generated during inhomogeneous dislocation nucleation. Finally, based on the above experimental and theoretical work as well as transmission electron microscopy observation, the influences of loading mode, loading rate, and material properties (stacking fault energy) on resulting intrinsic hardness of NC Ni and NC Ni-Fe alloy are analyzed. The nanoindentation approach developed in this study provides profound insights into the mechanical behaviors during loading and underlying mechanisms of materials.

Grain Size Prediction in SCR420HB Hot Forging: Combining Phenomenological and JMAK Models with Experimental and Numerical Analysis

This study presents the enhancement of a phenomenological model for predicting grain size evolution during the hot deformation of SCR420HB bearing steel. The model now incorporates strain rate and temperature as controllable variables, thereby improving prediction accuracy for various combinations of these factors. Material’s microstructural constants, including initial grain size exponent, strain exponent, strain rate exponent, and dynamic recrystallization activation energy, were determined through FEM-coupled optimization techniques. Accurate flow stress data, crucial for determining the onset of dynamic recrystallization, was integrated to enhance the model's precision. The accuracy of the optimized model was validated by comparing predicted and experimental grain sizes across different stages of the hot forging process, demonstrating improved model performance. Additionally, the study provides insights into the sensitivity of the grain size to different deformation conditions, offering valuable guidance for industrial forging applications. This comprehensive approach ensures the model's robustness and practical applicability in real-world scenarios.

Optimization of Forming Parameters of Ti-3Al-2.5V Titanium Tubes by Differential Heating Push-Bending Based on a Modified Johnson−Cook Constitutive Model

This study addresses the challenges associated with the difficult formation and low quality of formed Ti-3Al-2.5V titanium alloy thin-walled tubes with small bending radii (r / D < 1.5, where r is the bending radius, D is the outer diameter of the tube) by proposing a differential heating push-bending (DHP-B) forming approach. Initially, the stress−strain curves of Ti-3Al-2.5V at various strain rates and temperatures were obtained through high-temperature uniaxial tensile tests. Subsequently, a modified Johnson−Cook (JC) model for Ti-3Al-2.5V within the temperature range of 25℃ to 800℃ was developed to enhance the accuracy of the finite element model. Based on the static implicit and dynamic explicit algorithms, a thermomechanically coupled finite element model for differential heating push-bending of titanium alloy thin-walled tubes has been established. Taking the heating temperature, friction coefficient, counterthrust force and rubber block thickness as the optimization parameters, the prediction model of the maximum wall thinning rate and thickening rate is obtained by using the response surface method, and the best parameter combination is obtained via the NSGA-II algorithm and the minimum distance selection method, which realizes the optimization of differential heating push-bending parameters, as verified by experiments in which the maximum wall-thinning rate is reduced to 9%, and the maximum wall thickness thickening rate is reduced to 14.2%, which improves the forming quality of the titanium tube.

Effects of twin thickness, strain rate, and temperature on the mechanical properties of nanotwinned diamond

Effects of twin thickness, strain rate, and temperature on the mechanical properties of nanotwinned diamond

Permanent deformation and particle crushability of calcareous sands under cyclic traffic-induced loadings through simple shear apparatus

This study focuses on investigating permanent deformations, encompassing normal and shear strains, of calcareous sandy soils subjected to drained cyclic traffic-induced loadings. The investigation utilizes a Simple Shear (SS) apparatus allowing for variations in both normal and shear stress components over each cycle and incorporates Principal Stress Rotation (PSR), a feature not replicable in conventional cyclic uniaxial triaxial tests which is the key aspect of this research. The study also accounts for the harmonically changing the effective horizontal stress resulting from cyclic variations of effective vertical stress, conducted under a horizontally constrained boundary condition with zero lateral strain. A series of drained cyclic simple shear experiments is carried out, implementing a heart-shaped stress path, encompassing up to 1000 cycles. The objective of the study is to analyze permanent normal and shear deformations, along with associated total particle crushing, using both sieving analyses and 2D image processing of particles. The study also evaluates the impact of an initial static shear stress originating from the longitudinal slope of roads. The findings highlight the influences of induced cyclic amplitudes of stress components, principal stress and strain rate rotation, and initial static shear stress on the development of permanent strains. Furthermore, the research characterizes particle crushability in terms of total crushability over such loading, examining its dependency on relative density and variations in both shear and normal stress components.

Effect of microstructure on dynamic response of ferrite matrixed steel at high strain rates

Dynamic response of steels at high strain rates are of great practical significance for understanding mechanical structures under extreme load conditions. To explore the relationship between structure and stress during dynamic deformation at high strain rates, steel specimens were prepared with varied microstructures of ferrite, ferrite and pearlite, and ferrite and spherical carbide. It is revealed that different microstructured steels exhibit drastically different characteristic of waves excited by the instantaneous impact of a servo-hydraulic tensile testing. It is also observed that a beat frequency response exists under dynamic deformation at certain high strain rates. It is therefore proposed that dynamic plastic deformation starts with stress fluctuation with a dislocation damped vibration model, and two successively excited waves are superimposed to form the beat frequency response.

Dynamic deformation and fracture of brass: Experiments and dislocation-based model

In this work, we perform a comprehensive study of the dynamic deformation and fracture of brass, including Taylor tests with classical and profiled cylinders and ball throwing experiments reaching the strain rates of about (0.1−1)/μs, as well as atomistic and continuum-level numerical modeling. Molecular dynamics (MD) simulations are used to construct the equation of state (EOS) of brass and to study its fracture characteristics at shear deformation under negative pressure. An original model of fracture under combined tensile-shear loading is formulated, which takes into account both the accumulation of empty volume in the process of lattice loosening due to the lattice defect production in the course of plastic deformation and further mechanical growth of voids controlled by the dislocation plasticity. This atomic-scale model is transmitted to the macroscopic experiment-scale level and embedded into 3D dislocation plasticity model to describe the dynamic deformation and fracture of brass using the numerical scheme of smoothed particle hydrodynamics (SPH). A part of experimental data is used to find the optimal parameters of the dislocation plasticity model by means of the Bayesian global optimization method accelerated with the help of artificial-neural-network (ANN)-based emulator of the 3D model. Another part of experimental data is used to fit the fracture model parameter. The remaining experimental data, which are not used in the parameterization, are applied to verify the parameterized model. The developed physical-based model provides correct and meaningful description of the dynamic deformation and fracture of brass, while the developed formalized approach to its parameterization opens a way to wider use of this type of models in the engineering applications, including studies on dynamic performance and high-speed processing technologies.

Thermodynamically consistent phase-field model for pressure-induced multiphase phase transformation of metals under intensive dynamic loading

Understanding the pressured-induced multiphase phase transformation (MPT) of metals at high strain rate is of great technical and scientific interest. Despite of several decades of studies, the pressured-induced MPT of metals at high strain rate is far from well understood because the deformation at high strain rate is so complex that present in situ diagnostic techniques or atomistic simulations cannot provide the details of the MPT at high strain rate. In the current work, a multiphase phase-field (MPF) model for the dynamic phase transformation (PT) of metals is developed, in which the volume fraction of each phase is chosen as the order parameter. The driving force of the MPT consists of the Gibbs free energy, the gradient energy and the penalizing energy. In particular, a smooth and normalized interpolation function is introduced to establish the Gibbs free energy at the multiphase junction. With the aid of this interpolation function, the explicit forms of the kinetics equation and constitutive relations of the MPT at the multiphase junction are also derived. It is demonstrated that the model satisfies all seven criteria of a consistent MPF model. Compared to previous models, the thermodynamic stability of this model is improved significantly. When applied to address the MPT of bismuth subjected to ramp-wave loading (RWL), the model can quantify the connection between the microstructural evolution of multiple phases and the experimentally measured multiwave structures.Moreover, new insights concerning the MPT-related thermodynamic paths of bismuth at elevated temperatures and the metastable phase during dynamic MPT are gained.

Effect of loading frequency on tensile fatigue behavior of ultra-high-strength engineered cementitious composites

The ultra-high-strength engineering cementitious composites demonstrates pseudo strain hardening behavior when subjected to uniaxial tension, making it a promising material for enduring repeated or fatigue loads. Extensive research has been conducted on the quasi-static, dynamic, and fatigue behavior of this composites. However, due to the challenges of conducting direct tensile testing on concrete, investigations into the tensile fatigue behavior of ECC, particularly for ultra-high-strength ECC, remain limited. The fatigue behavior of concrete can be influenced by various factors. This study focuses on the impact of loading frequency. Several series of tensile fatigue tests were conducted under different loading frequencies and stress levels. The test results revealed that fatigue life increases with higher applied loading frequencies and decreases with increasing stress levels. The analysis of the test results includes the examination of failure modes, fatigue life, deformation, and secondary strain rates. A probabilistic model of fatigue failure, considering the discreteness of the initial static strength, was proposed based on the fatigue life. This model aligned well with the experimental results, providing valuable insights into the behavior of ultra-high-strength ECC under tensile fatigue conditions

Solidification cracking susceptibility of alloy 718 during additive manufacturing and evaluating method

Although hot cracks frequently occur during metal additive manufacturing (AM), there are very few fundamental studies on the cracking behaviour and susceptibility. In this study, a horizontal tensile-type hot cracking test was investigated for evaluating the solidification cracking susceptibility of alloy 718 quantitatively during AM, particularly in laser powder bed fusion. The factors influencing the cracking susceptibility were also examined. The solidification cracking was reproduced by the melting of the AMed specimen with a tensile load under conditions of heat source simulating the AM process. The critical initial tensile stress for solidification crack initiation could apply as an evaluation index for cracking susceptibility. The critical initial stress decreased with increasing the laser power. A similar tendency was observed during the melting of the powders set on tiny groove for simulating AM process. The critical strain rate for solidification cracking (CST) was derived by a thermal elastic–plastic analysis using the critical initial stress measured experimentally. The CST at the laser power of 1125 W was higher than that of 1000 W for no crack condition. Therefore, high CST corresponding to penetration shape with high laser power induce to deteriorate the solidification cracking susceptibility.

Dynamic formation of gradient structure by microparticle impact — A crystal plasticity material point method study

Metallic materials with unique microstructure can achieve desirable strength-ductility synergy. However, effectively fabricating and precisely controlling microstructure distribution in metals remain challenging. Microparticle impact, the key process of cold spray technique, can lead to a gradient structure in the particle, which may also serve as a promising additive manufacturing technology. To investigate the dynamic formation mechanism of heterogeneous microstructure and its significant influencing factors, the crystal plasticity material point method (CPMPM) is developed, especially for microstructure formation under a high strain rate and large deformation. Our work provides a quantitative analysis of evolution of structural gradient during impact. It is found that decreasing grain size can afford a larger structural gradient and there is negligible influence on the compression ratio of particles. It suggests that microstructure distribution can be tailored by optimizing the impact process without influencing vertical deformation of particles.

Heat Transfer and Entropy Generation in Vibrational Flow: Newtonian vs. Inelastic Non-Newtonian Fluid

A computational method is employed to solve heat transfer and entropy generation within a circular pipe. The thermal boundary condition assumes a constant wall temperature, while viscosity is taken to be dependent on temperature. A power-law type shear-thinning fluid is utilized in the analysis, with sinusoidal vibration applied horizontally perpendicular to the flow direction. Temperature distributions across the pipe are illustrated. Additionally, the entropy generation rate over the entire fluid volume under vibration was examined, comparing the results between steady flow and vibrational flow for both types of fluids. It was found that radial mixing is more pronounced in non-Newtonian fluids as vibration increases the strain rate, which is higher for low Reynolds numbers. The research provides a quantitative analysis of heat transfer and entropy generation for both Newtonian and shear-thinning fluids at different Reynolds numbers. It was observed that the effectiveness of superimposed vibrational flow is limited, especially for low Reynolds numbers and flow behavior index characteristic of shear-thinning fluids.

A novel impact approach based on electromagnetic loading technology: A case study on CFRP/Al riveted structures

To investigate the mechanical response and damage behavior of aircraft fuselage composite structures under out-of-plane impact loads more efficiently and flexibility, this paper proposed a novel impact approach and testing platform based on inductive coils to yield electromagnetic impact force. The influence of system key parameters on the electromagnetic loading waveforms were analyzed using an electromagnetic field finite element model. Single/repeated impact tests on CFRP/aluminium alloy (Al) riveted structures were conducted at different voltages (energies) based on this approach. The results indicate that the electromagnetic impact (EMI) approach exhibits significant advantages in both variable strain rate loading and continuous impact loading scenarios. This device can efficiently achieve multi-point and multiple impact loading. The electromagnetic impact forces with various amplitudes and pulse-widths can be accurately obtained by altering voltage and capacitance values, which can demonstrate the good experimental consistency of such test approach. Besides, with this test method, the load threshold for damage formation can be clearly defined: once the impact force exceeds the damage threshold load, the delamination area of the CFRP laminates expand as the impact energy increases. Note that when the provided out-of-plane impact load is slightly higher than the damage threshold load by changing the voltage, significant delamination damage may suddenly manifest in any one impact event of the repeated impacts.

Mechanical Properties of Superhigh-Strength Q960 Steel at Elevated Temperatures Considering the Tensile Strain Rate

Mechanical Properties of Superhigh-Strength Q960 Steel at Elevated Temperatures Considering the Tensile Strain Rate

Influences of Strain Rate and Density on the Dynamic Material Properties and Energy Dissipation Characteristics of Iron Tailing Porous Concrete

Influences of Strain Rate and Density on the Dynamic Material Properties and Energy Dissipation Characteristics of Iron Tailing Porous Concrete

Monitoring Slug Flow Using Distributed Acoustic Sensing Technology with Different Sensing Cable Configurations

Summary Monitoring slug flow in real time over long distances is essential for facility design, operation, and flow assurance management. In this study, we investigated the use of distributed acoustic sensing (DAS) technology for slug flow monitoring, exploring various cable designs and deployment methods. The experimentation encompassed the use of five distinctive fiber-optic cable deployment methods: three internal cables of varying designs (thin, flat, and thick), supplemented by two external cables—one placed straight atop the pipeline while the other was helically wrapped around it. All cables were connected consecutively and successfully captured the dynamic variation of the slugging phenomenon along the pipe. We introduce different data processing algorithms for slug flow characterization, including standard deviation (SD) downsampling, slug frequency determination, and semblance for velocity extraction. The experimental results indicate a higher slug frequency but smaller slug sizes near the inlet of upward inclined pipe, where most slug structures originate. The structure velocity shows a positive correlation with DAS amplitude or the maximum strain rate, which could be related to the slug size. The flat cable exhibited a heightened amplitude response to slugs, while the internal thin and the external straight cables provided the most distinct delineation of slug patterns. The internal thick cable provided the least sensitivity among all due to its design. Although the linear deployment of fiber-optic cables is more practical compared to helically wrapped ones, their resolution limits detailed analysis of more intricate slug characteristics for short pipelines, such as precise velocity measurements of slugs. Data from the helically wrapped cable can address these limitations, providing more comprehensive insights.