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In order to improve the understanding of damage evolution in mechanically heterogeneous microstructures, like the ones of dual-phase steels, the influence of the applied stress state is a key element. In this work, we studied the influence of the globally applied stress state on the evolution of damage in such a microstructure. Classical damage models allow predictions of damage during deformation based on considerations of the material as an isotropic continuum. Here, we investigate their validity in a dual phase microstructure that is locally dominated by its microstructural morphological complexity based on a statistical ensemble of thousands of individual voids formed under different stress states. For this purpose, we combined a calibrated material model incorporating damage formation to assess the local stress state in samples with different notch geometries and high-resolution electron microscopy of large areas using a deep learning-based automated micrograph analysis to detect and classify microstructural voids according to their source of origin. This allowed us to obtain both the continuum stress state during deformation and statistically relevant data of individual void formation. We found that the applied plastic strain is the major influence on the overall number, and therefore the nucleation of new voids, while triaxiality correlates with the median void size, supporting its proposed influence on void growth. In contrast, coalescence of voids leading to failure appears related to local instabilities in the form of shear band formation and is therefore only indirectly determined by the global stress state in that it determines the global distribution, density and size of voids., Comment: 20 pages, 11 figures

Many studies have examined the damage behaviour of dual-phase steels already. It is a topic of high interest, since understanding the mechanisms of damage during forming processes enables the production of steels with improved properties and damage tolerance. However, the focus was rarely on the comparison between representatives of this steel class, and the numerical simulation for the quantification of damage states was not thoroughly used. Therefore, this study compares the damage initiation and accumulation of two dual-phase steels (DP800 and DP1000), which are used in the automotive industry. Additionally, parameter sets of a phenomenological damage mechanics model with coupled damage evolution are calibrated for each material. The combined analysis reveals an earlier initiation of damage for the DP800, where the damage accumulation phase is prolonged. For DP1000 the damage nucleates only shortly before material failure. The material model is able to correctly predict the behaviour, while experimental analysis confirms the prediction via light optical and SEM metallography.