The Numerical Simulation Application for Fire-Tube Boiler Heating Surface Safety Evaluation

The numerical simulation is applied for fire-tube boiler heating surface safety estimation. Thermal processes in an inflatable fire-tube furnace during its emergency operation were simulated using the finite volume method with Euler approximation and the implicit pressure based algorithm. Study results reproduce failures connected with increasing of impasse aerodynamic resistance. The method of these failures prediction is suggested. Simulation has shown that entering the amount of coolant into combustion volume results in burner fan incapability to overcome the impasse resistance of the furnace. The simulation results are visually confirmed during the inspection of emergency boilers

Micromechanical effect of martensite attributes on forming limits of dual-phase steels investigated by crystal plasticity-based numerical simulations

This study analyses the effect of martensite grain size and its volume fraction in dual-phase (DP) steel on (1) the formability limit, (2) average global behavior under different loading conditions, and (3) damage initiation. The virtual RVEs (Representative Volume Elements) were constructed using DREAM.3D software with a variation of microstructural attributes. The numerical simulations were carried out using DAMASK, which evaluates the polycrystalline material point behavior and solves versatile constitutive equations using a spectral solver. The simulations were post-processed to obtain global and local stress, strain, and damage evolution in constructed RVEs. The global results were processed to obtain FLDs according to Keeler-Brazier (K-B) and Marciniak and Kuczynski (M-K) criteria. In this work, the capability of microstructure-based numerical simulations to analyze the FLDs has been established successfully. From Forming Limit Diagrams (FLDs), it was observed that formability changes by changing the strain hardening coefficients (n-values), the martensite fraction, and martensite grain sizes of DP steels. The improved formability was observed with lower martensite fraction, i.e., 17%, decreased martensite grain size, i.e., 2.6 µm, and higher strain hardening coefficient. The M-K approach shows the better capability to predict the formability by various loading conditions and clarifies the necking marginal zone of FLD. The damage propagation is also strongly affected by the loading conditions. The current study would be a good guide for designers during the manufacturing and selecting of appropriate DP steels based on the service loading conditions

Studying the Damage Evolution and the Micro-Mechanical Response of X8CrMnNi16-6-6 TRIP Steel Matrix and 10% Zirconia Particle Composite Using a Calibrated Physics and Crystal-Plasticity-Based Numerical Simulation Model

The mechanical behavior of newly developed composite materials is dependent on several underlying microstructural phenomena. In this research, a periodic 2D geometry of cast X8CrMnNi16-6-6 steel and 10% zirconia composite is virtually constructed by adopting microstructural attributes from literature. A physics-based crystal plasticity model with ductile damage criterion is used for defining the austenitic steel matrix. The zirconia particles are assigned elastic material model with brittle damage criterion. Monotonic quasi-static tensile load is applied up to 17% of total strain. The simulation results are analyzed to extract the global and local deformation, transformation, and damage behavior of the material. The comprehensively constructed simulation model yields the interdependence of the underlaying microstructural deformation phenomena. The local results are further analyzed based on the interlocked and free regions to establish the influence of zirconia particles on micro-mechanical deformation and damage in the metastable austenite matrix. The trends and patterns of local strain and damage predicted by the simulation model results match the previously carried out in-situ tensile tests on similar materials

Applications of Crystal Plasticity in Forming Technologies

The Special Issue on ‘Crystal Plasticity in Forming Technologies’ is a collection of 11 original articles dedicated to theoretical and experimental research that provides new insights and practical findings in topics related to crystal plasticity [...

Powder Forging of in Axial and Radial Direction Graded Components of TRIP-Matrix-Composite

Powder metallurgy is one way of producing complex, graded structures that could allow material systems to be produced with properties tailored to individual applications. However, powder metallurgy requires that the semi-finished products are very similar to the final component. It is much more economical to produce simple semi-finished products and then combine them by powder forging and simultaneous compaction than forming complex components with the desired graded structure. However, it is absolutely necessary that the graded structure of the semi-finished products is maintained during the forming process. In this study, pre-sintered cylindrical semi-finished products, consisting of axially graded as well as radially graded components, were produced by powder forging at 1100 °C. The microstructures, densities and mechanical properties of the final components were investigated to verify the effectiveness of the process route. It was observed that the components formed solid structures after compaction, in which the reinforcing ZrO2 particles were fully integrated into the transformation-induced plasticity steel matrix

On Attempting to Create a Virtual Laboratory for Application-Oriented Microstructural Optimization of Multi-Phase Materials

Physics-based and phenomenological crystal plasticity numerical simulations provide an opportunity to develop microstructurally informed models for multi-phase material. The Düsseldorf Advanced Material Simulation Kit (DAMASK) has been developed as a flexible tool for modeling and studying the several deformation mechanisms of such materials at the microscopic and macroscopic scales. In the recent past, several methodologies and techniques were developed for obtaining or constructing microstructural details and calibrating the physics-based model parameters for single-phase and multi-phase materials. Combining and standardizing the devised methods with an appropriate database can help establish a virtual laboratory to analyze the effect of microstructural attributes on the mechanical behavior of multi-phase materials. This article deals with the comprehensive background of the developed techniques and methods for the multi-phase materials class by the current research group. The combinations of different experimental and numerical techniques to validate results are explained along with the advantages and limitations. The ideas of combining the different available tools and the associated challenges are discussed. The article presents some recent work related to the phase parameters identification of the multi-phase materials and detailed insight into the obtained results

Modeling the Local Deformation and Transformation Behavior of Cast X8CrMnNi16-6-6 TRIP Steel and 10% Mg-PSZ Composite Using a Continuum Mechanics-Based Crystal Plasticity Model

A Transformation-Induced Plasticity (TRIP) steel matrix reinforced with magnesium-partially stabilized zirconia (Mg-PSZ) particles depicts a superior energy absorbing capacity during deformation. In this research, the TRIP/TWIP material model already developed in the framework of the Düsseldorf Advanced Material Simulation Kit (DAMASK) is tuned for X8CrMnNi16-6-6 TRIP steel and 10% Mg-PSZ composite. A new method is explained to more accurately tune this material model by comparing the stress/strain, transformation, twinning, and dislocation glide obtained from simulations with respective experimental acoustic emission measurements. The optimized model with slight modification is assigned to the steel matrix in 10% Mg-PSZ composite material. In the simulation model, zirconia particles are assigned elastic properties with a perfect ceramic/matrix interface. Local deformation, transformation, and the twinning behavior of the steel matrix due to quasi-static tensile load were analyzed. The comparison of the simulation results with acoustic emission data shows good correlation and helps correlate acoustic events with physical attributes. The tuned material models are used to run full phase simulations using 2D Electron Backscatter Diffraction (EBSD) data from steel and 10% Mg-PSZ zirconia composites. Form these simulations, dislocation glide, martensitic transformation, stress evolution, and dislocation pinning in different stages of deformation are qualitatively discussed for the steel matrix and ceramic inclusions

Micromechanical Effect of Martensite Attributes on Forming Limits of Dual-Phase Steels Investigated by Crystal Plasticity-Based Numerical Simulations

This study analyses the effect of martensite grain size and its volume fraction in dual-phase (DP) steel on (1) the formability limit, (2) average global behavior under different loading conditions, and (3) damage initiation. The virtual RVEs (Representative Volume Elements) were constructed using DREAM.3D software with a variation of microstructural attributes. The numerical simulations were carried out using DAMASK, which evaluates the polycrystalline material point behavior and solves versatile constitutive equations using a spectral solver. The simulations were post-processed to obtain global and local stress, strain, and damage evolution in constructed RVEs. The global results were processed to obtain FLDs according to Keeler-Brazier (K-B) and Marciniak and Kuczynski (M-K) criteria. In this work, the capability of microstructure-based numerical simulations to analyze the FLDs has been established successfully. From Forming Limit Diagrams (FLDs), it was observed that formability changes by changing the strain hardening coefficients (n-values), the martensite fraction, and martensite grain sizes of DP steels. The improved formability was observed with lower martensite fraction, i.e., 17%, decreased martensite grain size, i.e., 2.6 µm, and higher strain hardening coefficient. The M-K approach shows the better capability to predict the formability by various loading conditions and clarifies the necking marginal zone of FLD. The damage propagation is also strongly affected by the loading conditions. The current study would be a good guide for designers during the manufacturing and selecting of appropriate DP steels based on the service loading conditions