An adaptive multi-level model for multi-scale ductile fracture analysis in heterogeneous aluminum alloys

This paper addresses the multi-scale modeling of ductile fracture in microstructures characterized by a dispersion of hard and brittle heterogeneities in a softer ductile matrix. An adaptive multi-level model is developed with different inter-scale transfer operators and interfaces. Micro-mechanical analysis in regions of dominant damage is performed to capture the important micro-mechanical damage modes that are responsible for deterring the overall failure properties of these alloys. Regions of macroscopic homogeneity are otherwise modeled with constitutive relations derived from homogenization of evolving variables in representative volume elements. These two length scales of analysis, in conjunction with an intermediate swing level, form a three-level coupled multi-scale model to capture ductile crack propagation. The capabilities of the proposed model are demonstrated for a cast aluminum alloy

Review of the Synergies Between Computational Modeling and Experimental Characterization of Materials Across Length Scales

With the increasing interplay between experimental and computational approaches at multiple length scales, new research directions are emerging in materials science and computational mechanics. Such cooperative interactions find many applications in the development, characterization and design of complex material systems. This manuscript provides a broad and comprehensive overview of recent trends where predictive modeling capabilities are developed in conjunction with experiments and advanced characterization to gain a greater insight into structure-properties relationships and study various physical phenomena and mechanisms. The focus of this review is on the intersections of multiscale materials experiments and modeling relevant to the materials mechanics community. After a general discussion on the perspective from various communities, the article focuses on the latest experimental and theoretical opportunities. Emphasis is given to the role of experiments in multiscale models, including insights into how computations can be used as discovery tools for materials engineering, rather than to "simply" support experimental work. This is illustrated by examples from several application areas on structural materials. This manuscript ends with a discussion on some problems and open scientific questions that are being explored in order to advance this relatively new field of research.Comment: 25 pages, 11 figures, review article accepted for publication in J. Mater. Sc

The role of aggregates in the thermal stability of Mg-PSZ refractories for vacuum induction melting

Mg-PSZ refractories used as vacuum induction melting crucibles are particle-reinforced composites with aggregate and matrix phases comprising fused zirconia. Three commercial varieties were cycled eight times to service temperatures and their microstructural and thermomechanical evolution investigated, with focus placed on the aggregate populations. Two refractories, with large aggregates of similar size, were found to retain stiffness after cycling but in the refractory containing aggregates with high stabiliser levels, reaction between the stabiliser and Al and Si impurities produced secondary phases. Volume changes accompanying formation of these phases, and subsequent thermal expansion mismatches, led to aggregate break-up with consequent reductions in refractory toughness and strength. Secondary phases developed only rarely in the aggregates (with lower levels of stabiliser) of the second refractory. These aggregates remained intact and the refractory retained its toughness and strength. A third refractory contained small, unstabilised aggregates in a stabilised matrix and the strain mismatches that ensued during polymorphic transformation damaged microstructural interfaces. Refractory stiffness halved within eight cycles and toughness and strength were lost. All three refractories displayed R-curve behaviour and quasi-stable fracture curves were observed during bend tests. The study shows that when using fused zirconia aggregates to design refractories, engineers need to i) limit stabiliser concentrations - a difference of just ±1 wt% Mg (in the presence of impurity elements) may determine whether secondary phase formation occurs and ii) eliminate alumina and silica impurities when possible through substitution of zircon sand with baddeleyite as the source for fused zirconia.Open Acces

Numerical thermo-elasto-plastic analysis of residual stresses on different scales during cooling of hot forming parts

In current research, more and more attention is paid to the understanding of residual stress states as well as the application of targeted residual stresses to extend e.g. life time or stiffness of a part. In course of that, the numerical simulation and analysis of the forming process of components, which goes along with the evolution of residual stresses, play an important role. In this contribution, we focus on the residual stresses arising from the austenite-to-martensite transformation at microscopic and mesoscopic level of a Cr-alloyed steel. A combination of a Multi-Phase-Field model and a two-scale Finite Element simulation is utilized for numerical analysis. A first microscopic simulation considers the lattice change, such that the results can be homogenized and applied on the mesoscale. Based on this result, a polycrystal consisting of a certain number of austenitic grains is built and the phase transformation from austenite to martensite is described with respect to the mesoscale. Afterwards, in a two-scale Finite Element simulation the plastic effects are considered and resulting residual stress states are computed