Search

A new type of gradient structure is fabricated by the sequential processing of two advanced severe plastic deformation methods, single-roll angular-rolling and ultrasonic nanocrystalline surface modification, which refine microstructures mainly on the core and surface of a metallic sheet, respectively. This material with a multi-layered grain size gradient in the thickness direction features impressive strength-toughness synergy beyond the initial and reverse gradient-structured materials. The superiority is attributable to hetero-deformation induced mechanisms that originate from microstructural heterogeneity. Ultimately, this work suggests a new processing approach by which a strength-toughness window saturated at a certain level in gradient-structured materials can be extended.

Constitutive modeling of CoCrFeMnNi high-entropy alloy (HEA) at cryogenic temperature (77 K) and room temperature (293 K) has been investigated. The effect of temperature on deformation behavior such as twinning, forest hardening, and back stress hardening has been established. The enhanced ductility and strength of CoCrFeMnNi HEA at 77 K are due the combination of sub-grain structure, twinning, and dislocations. This phenomenon is explained in terms of quantitative values of twin volume fraction, inter-twin spacing, and dislocation density. The isotropic kinematic constitutive model is constructed with a critical twinning stress parameter to obtain the criteria for twinning initiation. The developed finite element model simulation results at 77 K and 293 K are in good agreement with the experimental data. The model displays a smooth increase in the twin volume fraction until fracture point (maximum twin fraction region). Also, different modeling parameters are obtained for each temperature to account for the changing deformation behavior.

This paper reports the mechanical properties and formability under biaxial stretching in pure tantalum as a function of average grain size. The grain size of pure tantalum was adjusted from submicron to tens of micron using the high-pressure torsion process and subsequent annealing. The stretch formability was evaluated using a miniaturized Erichsen tester. Under uniaxial tension, the mechanical properties of pure tantalum followed the typical strength-ductility trade-off behavior according to the average grain size. Nevertheless, the stretch formability became rather significantly inferior in the coarse-grain tantalum, which was primarily attributed to the poor resistance to strain localization and limited work hardening capacity. This deterioration was supposed to be due to the intensified strain localization with increasing the average grain size, based on the in-grain deformation heterogeneity within individual grains and the surface roughening after the Erichsen test. Consequently, this study suggests that the excellent stretch formability and work hardening capacity under biaxial loading can be achieved at a certain range of the average grain size (8.25–19.3 μm in this work).

To clarify the direction of microstructure design for improving stretch-flangeability, relationships of stretch-flangeability to microstructure and mechanical properties of ultra-high-strength dual-phase (DP) steels were investigated. Microstructure of relatively simple ferrite-martensite DP steels was modified by intercritical annealing, then the effects of microstructure modification on stretch-flangeability, tensile properties, and fracture resistance of the DP steels were systematically quantified. The hole-expansion ratio (HER) increased linearly with an increase the apparent fracture initiation energy, but was not significantly correlated with any individual microstructural properties of DP steels, which have been reported to correlate with HER (e.g., the fraction of martensite, the carbon content of martensite, or the hardness difference between ferrite and martensite). To increase the stretch-flangeability of an ultra-high-strength DP steels, its microstructure should be designed to increase its fracture toughness (i.e., microstructure with low mechanical heterogeneity).

An essential task in materials science and engineering is in quantifying the linkages between physical variables of a material to its properties. These linkages are both complex and computationally expensive to quantify, as evidenced by rigorous modeling efforts and time-consuming simulations. Hence, practicality dictates that tasks such as materials design that require numerous evaluations are largely limited to qualitative assessment or traditional trial and error. In this work, microstructure-based simulations with model parameters calibrated to reproduce experimental data are employed to make a qualitative assessment of how physical variables of dual-phase steel are correlated to its properties. Afterward, the linkages between physical variables of dual phase steel to its property are computed with a limited amount of microstructure-based simulation data by adopting the Bayesian approach, namely Gaussian process regression (GPR). Even with a small amount of data, GPR yielded an impressive level of accuracy. Furthermore, because microstructure-based simulations are based on experimental data, the quantified linkages are transferable to experimental data.

The effect of grain size on stretch-flangeability was investigated to determine its influence on stretch-flangeability of high strength steels. To avoid other effects of microstructure, single-phase twinning-induced plasticity (TWIP) steels were selected for the investigation. To control the grain size of two types of TWIP steels, 1) the initial specimen was annealed at 1100 ℃ to increase its grain size, or 2) subjected to high-pressure torsion then annealed at 650 ℃ to reduce the grain size. The microstructural features were analyzed using the electron backscatter diffraction. The stretch-flangeability of TWIP steels with various grain sizes was evaluated using a hole-expansion test. It was found that the hole-expansion ratio follows the Hall-Petch correlation as does fracture toughness. To improve the stretch-flangeability of high strength steels, microstructural features should be designed to increase their fracture toughness.

In the present study, the effect of secondary phase particles and deformation localization on tensile behaviors of Mg-Zn-Ca alloy were investigated using micro-digital image correlation method. To isolate the effect of the secondary phase particles on tensile behavior, the fractions of the secondary phase particles were adjusted by controlling the annealing temperature. Thermodynamic calculations were performed to identify the fractions of the secondary phase particles. The finite element method was conducted to confirm the localized deformation around the secondary phase particles considering 3-dimensional microstructure. The results suggest that the total fraction of the secondary phase particles affected the localized deformation around the particles and micro-crack propagation process during a tensile test.

In this work, the mechanical characteristics and microstructural evolution of Al0.5CoCrFeMnNi high-entropy alloy (HEA) were studied after annealing at various temperatures (1000, 1100, and 1200 °C). X-ray diffraction, scanning electron microscopy, and energy dispersive spectroscopy analyses were performed to reveal the phase and microstructural variations. The mechanical properties related to different microstructures of the alloy were characterized using tensile testing with digital image correlation. Annealing at lower temperatures led to a higher fraction of B2 phase and finer grain size of FCC (face-centered cubic) phase. A good combination of strength and ductility in this alloy was attributed to the ductile FCC matrix and hard secondary B2 phase. The alloy showed the active evolution of deformation twinning due to the low stacking fault energy when Al was added to CoCrFeMnNi to make the HEA. However, for alloy annealed at lower temperatures, twinning activity was suppressed by the smaller size of grains and depletion of Al content in the FCC matrix. The correlation between the microstructure and mechanical properties was also explored using a simple composite model.

Herein, the deep drawability and deep drawing behavior of an equiatomic CoCrFeMnNi HEA and its microstructure and texture evolution are first studied for future applications. The CoCrFeMnNi HEA is successfully drawn to a limit drawing ratio (LDR) of 2.14, while the planar anisotropy of the drawn cup specimen is negligible. The moderate combination of strain hardening exponent and strain rate sensitivity and the formation of deformation twins in the edge region play important roles in successful deep drawing. In the meanwhile, the texture evolution of CoCrFeMnNi HEA has similarities with conventional fcc metals.

Stretch-flangeability measured using hole expansion test (HET) represents the ability of a material to form into a complex shaped component. Despite its importance in automotive applications of advanced high strength steels, stretch-flangeability is a less known sheet metal forming property. In this paper, we investigate the factors governing hole expansion ratio (HER) by means of tensile test and HET. We correlate a wide range of tensile properties with HERs of steel sheet specimens because the stress state in the hole edge region during the HET is almost the same as that of the uniaxial tensile test. In order to evaluate an intrinsic HER of steel sheet specimens, the initial hole of the HET specimen is produced using a milling process after punching, which can remove accumulated shearing damage and micro-void in the hole edge region that is present when using the standard HER evaluation method. It was found that the intrinsic HER of steel sheet specimens was proportional to the strain rate sensitivity exponent and post uniform elongation.

Stretch-flangeability representing the capability of a sheet material to form into a complex shaped part is not a well-known sheet metal forming property. We correlate mechanical properties with stretch-flangeability of various advanced high strength steels (AHSSs) to capture the stretch-flanging phenomenon and improve the stretch-flangeability of steel sheet materials. The stretch-flangeability of materials is usually evaluated using a hole expansion test. During the hole expansion test, the stress state in the hole edge part of the specimen is almost the same as that of the uniaxial tensile test. However, a single parameter in tensile properties of the AHSSs exhibits no clear correlation with flangeability estimated as the hole expansion ratio (HER). Because micro-cracks in the hole edge region of the hole expansion testing samples play a significant role in HER values, we propose and demonstrate that fracture toughness is the key factor governing the HER of AHSSs.

A martensitic TiNi shape memory alloy was processed by high-pressure torsion (HPT) for 1.5, 10 and 20 turns followed by post-deformation annealing (PDA) at 673 and 773 K for various times in order to study the microstructural evolution during annealing and the shape memory effect (SME). Processing by HPT followed by the optimum PDA leads to an appropriate microstructure for the occurrence of a superior SME which is attributed to the strengthening of the martensitic matrix and grain refinement. A fully martensitic structure (B19' phase) with a very small grain size is ideal for the optimum SME. The results indicate that the nanocrystalline microstructures after PDA contain a martensitic B19' phase together with an R-phase and this latter phase diminishes the SME. Applying a higher annealing temperature or longer annealing time may remove the R-phase but also reduce the SME due to grain growth and the consequent decrease in the strength of the material. The results show the optimum procedure is a short-term anneal for 10 min at 673 K or only 1.5 min at 773 K after 1.5 turns of HPT processing to produce a maximum recovered strain of ~8.4% which shows more than 50% improvement compared with the solution-annealed condition.

A martensitic NiTi shape memory alloy was processed successfully by equal-channel angular pressing (ECAP) for one pass at room temperature using a core–sheath billet design. The annealing behavior and shape memory effect of the ECAP specimens were studied followed by post-deformation annealing (PDA) at 673 K for various times. The recrystallization and structural evolution during annealing were investigated by differential scanning calorimetry, dilatometry, X-ray diffraction, transmission electron microscopy and microhardness measurements. The results indicate that the shape memory effect improves by PDA after ECAP processing. Annealing for 10 min gives a good shape memory effect which leads to a maximum in recoverable strain of 6.9 pct upon heating where this is more than a 25 pct improvement compared with the initial state.

A NiTi alloy was processed by high-pressure torsion for 10 turns followed by post-deformation annealing at 673 K for various times. An anneal for 60 min gave a nanocrystalline microstructure with a superior shape memory effect and an improvement of more than 40% over the initial state.

Deformation twinning from grain boundaries is often observed in face-centered cubic metals with low stacking fault energy. One of the possible factors that contribute to twinning origination from grain boundaries is the intergranular interactions during deformation. Nonetheless, the influence of mechanical interaction among grains on twin evolution has not been fully understood. In spite of extensive experimental and modeling efforts on correlating microstructural features with their twinning behavior, a clear relation among the large aggregate of grains is still lacking. In this work, we characterize the micromechanics of grain-to-grain interactions that contribute to twin evolution by investigating the mechanical twins near grain boundaries using a full-field crystal plasticity simulation of a twinning-induced plasticity steel deformed in uniaxial tension at room temperature. Microstructures are first observed through electron backscatter diffraction technique to obtain data to reconstruct a statistically equivalent microstructure through synthetic microstructure building. Grain-to-grain micromechanical response is analyzed to assess the collective twinning behavior of the microstructural volume element under tensile deformation. Examination of the simulated results reveal that grain interactions are capable of changing the local mechanical behavior near grain boundaries by transferring strain across grain boundary or localizing strain near grain boundary. Grains that should not favour twin formation exhibit twinning as a result of surrounding grains acting on their boundaries. A team led by HyoungSeop Kim at the Pohang University of Science and Technology in the Republic of Korea simulated the deformation of synthetic metallic microstructures with many grains of different orientations, based on steels that deform by both dislocation slip and twinning mechanisms. Twinning first started near grain boundaries and depended on initial grain orientation but, with further deformation, strong twin activity on one side of a boundary triggered strong twin activity on the other side of that boundary. This happened even when the grain on the other side of the boundary was unfavourable to twinning. Taking into account grain neighbourhood may therefore help in optimising twin-forming alloys.

In this study, a serial sectioning technique was employed in order to visualize the three-dimensional (3D) structure, and to accurately simulate the mechanical and thermal behaviors of SiC particle-reinforced Al composites. Sequential, two-dimensional (2D) optical images of the microstructure were acquired after polishing, and then reconstructed to develop 3D geometries for microstructural analyses and finite element modeling. Experimental compressive and thermal expansion tests were performed for comparison with the finite element method results. The Young’s modulus and thermal expansion coefficient of the composite, predicted using the 3D microstructure-based finite element analyses, were in good agreement with the experimental results. Furthermore, the 3D microstructure-based finite element model showed anisotropic thermal expansion behavior that was previously disregarded in the other models used in this study. Therefore, it was confirmed that the combined approach of serial sectioning and finite element modeling provides a significant improvement over 2D and 3D unit-cell modeling.

The closure and contact bonding behavior of internal pores in steel slabs during hot rolling was studied using experiments and the finite element method (FEM). Effects of pore size and shape were investigated, and three different cases of pore closure results were observed: no closure, partial closure, and full closure. The FEM results well reproduced various closure events. Bonding strengths of unsuccessfully closed pores, measured by tensile tests, showed critical effects. Also, there was a difference in bonding strengths of several fully closed pores. Fracture surfaces showed that welded regions could be divided into three (not, partially, and perfectly) welded regions. The pressure–time curves obtained from the FEM results indicate that pore surface contact time and deformed surface length are important parameters in pore welding. Pore size, pore shape, time of pressure contact, and deformed surface length should be considered to completely eliminate pores in final products.