Synchrotron strain scanning for residual stress measurement in cold-drawn steel rods

Cold-drawn steel rods and wires retain significant residual stresses as a consequence of the manufacturing process. These residual stresses are known to be detrimental for the mechanical properties of the wires and their durability in aggressive environments. Steel makers are aware of the problem and have developed post-drawing processes to try and reduce the residual stresses on the wires. The present authors have studied this problem for a number of years and have performed a detailed characterization of the residual stress state inside cold-drawn rods, including both experimental and numerical techniques. High-energy synchrotron sources have been particularly useful for this research. The results have shown how residual stresses evolve as a consequence of cold-drawing and how they change with subsequent post-drawing treatments. The authors have been able to measure for the first time a complete residual strain profile along the diameter in both phases (ferrite and cementite) of a cold-drawn steel rod

Laser-Induced Spall Of Aluminum And Aluminum Alloys At High Strain Rates

We conducted laser-induced spall experiments aimed at studying how a material's microstructure affects the tensile fracture characteristics at high strain rates (> 10(6) s(-1)). We used the Z-Beamlet Laser at Sandia National Laboratory to drive shocks and to measure the spall strength of aluminum targets with various microstructures. The targets were recrystallized, high-purity aluminum (Al-HP RX), recrystallized aluminum + 3 wt.% magnesium (Al-3Mg RX), and cold-worked aluminum + 3 wt.% magnesium (Al-3Mg CW). The Al-3Mg RX and Al-3Mg CW are used to explore the roles that solid-solution alloying and cold-work strengthening play in the spall process. Using a line-VISAR (Velocity Interferometer System for Any Reflector) and analysis of recovered samples, we were able to measure spall strength and determine failure morphology in these targets. We find that the spall strength is highest for Al-HP RX. Analysis reveals that material grain size plays a vital role in the fracture morphology and spall strength results.Mechanical Engineerin

Spall And Dynamic Yielding Of Aluminum And Aluminum Alloys At Strain Rates Of 3X10(6) S(-1)

We have explored the role that grain size, impurity particles and alloying in aluminum play in dynamic yielding and spall fracture at tensile strain rates of similar to 3x10(6) We achieved these strain rates shocking the aluminum specimens via laser ablation using the Z-Beamlet Laser at Sandia National Laboratories. The high purity aluminum and 1100 series aluminum alloy produced very different spall strengths and nearly the same yield strengths. In contrast, various grain-sized Al + 3 wt. % Mg specimens presented the lowest spall strength, but the greatest dynamic yield strength. Fracture morphology results and particle analysis are presented along with hydrodynamic simulations to put these results in context. Impurity particles appeared to play a vital role in spall fracture at these fast strain rates. Alloying elements such as Mg seem to be the dominant factor in the dynamic yield results.Mechanical Engineerin

Creep fracture during solute-drag creep and superplastic deformation

Creep fracture behavior has been studied in Al-Mg and Al-Mg-Mn alloys undergoing solute-drag creep and in microduplex stainless steel undergoing both solute-drag creep and superplastic deformation. Failure in these materials is found to be controlled by two mechanisms, neck formation and cavitation. The mechanism of creep fracture during solute-drag creep in Al-Mg is found to change from necking-controlled fracture to cavitation-controlled fracture as Mn content is increased. Binary Al-Mg material fails by neck formation during solute-drag creep, and cavities are formed primarily in the neck region due to high hydrostatic stresses. Ternary alloys of Al-Mg- Mn containing 0.25 and 0.50 wt % Mn exhibit more uniform cavitation, with the 0.50 Mn alloy clearly failing by cavity interlinkage. Failure in the microduplex stainless steel is dominated by neck formation during solute-drag creep deformation but is controlled by cavity growth and interlinkage during superplastic deformation. Cavitation was measured at several strains, and found to increase as an exponential function of strain. An important aspect of cavity growth in the stainless steel is the long latency time before significant cavitation occurs. For a short latency period, cavitation acts to significantly reduce ductility below that allowed by neck growth alone. This effect is most pronounced in materials with a high strain-rate sensitivity, for which neck growth occurs very slowly

Superplastic deformation in two microduplex stainless steels

The deformation behavior and mechanisms of superplastic flow in two microduplex stainless steels (SuperDux64 and Nitronic 19D) were studied at {similar_to}0.7T{sub m}. The two steels differed in initial grain size by a factor of 3. Both steels exhibited solute-drag-controlled grain boundary sliding in a high temperature {gamma}+{delta} phase field. In a lower temperature {gamma}+{sigma} phase field, the fine-grained steel ({bar L}=5{mu}m) exhibited climb-controlled grain boundary sliding and the coarser- grained steel ({bar L}=15{mu}m) exhibited solute-drag-controlled slip creep

Enhanced tensile ductility in Al-Mg alloys by solid-solution interactions

The development of methods for obtaining high tensile elongation in aluminum alloys is of great importance for the practical forming of near-net-shape parts. Current superplastic alloys are limited in use by high material costs. The utilization of solute-drag creep processes, the approach used in this study, to obtain enhanced tensile ductility in aluminum alloys has lead to tensile elongations of up to 325% in simple, binary Al-Mg alloys with coarse grain sizes. This method has the advantage of lowering processing costs in comparison with superplastic alloys because a fine grain size is not necessary. Whereas superplastic alloys typically have a strain-rate sensitivity of m = 0.5, the enhanced ductility Al-Mg alloys typically exhibit m = 0.3 where maximum ductility is observed. Although a strain-rate sensitivity of rn = 0.5 can lead to elongations of over 1000% (superplastic materials) a value of m = 0.3 is shown experimentally to be sufficient for obtaining elongations of 150% to a maximum observed of 325%. Enhanced ductility is also affected strongly by ternary alloying additions, such as Mn, for which a preliminary understanding is pursued

Deformation mechanisms in superplastic AA5083 materials

The plastic deformation of seven 5083 commercial aluminum materials, produced from five different alloy heats, are evaluated under conditions of interest for superplastic and quick-plastic forming. Two mechanisms are shown to govern plastic deformation in AA5083 over the strain rates, strains, and temperatures of interest for these forming technologies: grain-boundary-sliding (GBS) creep and solute- drag (SD) creep. Quantitative analysis of stress transients following rate changes clearly differentiates between GBS and SD creep and offers conclusive proof that SD creep dominates deformation at fast strain rates and low temperature. Furthermore, stress transients following strain-rate changes under SD creep are observed to decay exponentially with strain. A new graphical construction is proposed for the analysis and prediction of creep transients. This construction predicts the relative size of creep transients under SD creep from the relative size of changes in an applied strain rate or stress. This construction reveals the relative size of creep transients under SD creep to be independent of temperature; temperature dependence resides in the “steady-state” creep behavior to which transients are related.General Motors Corporatio

Deformation and failure of a superplastic AA5083 aluminum material with a Cu addition

A modified AA5083 aluminum sheet material containing a Cu addition of 0.61 wt pct has been investigated under conditions relevant to commercial hot-forming technologies. This material was produced by continuous casting followed by industrial hot and cold rolling into sheet. Deformation and failure mechanisms at elevated temperatures were investigated through mechanical testing, thermal analysis, and microscopy. The effects of Cu addition are evaluated by comparisons with data from AA5083 sheet materials without Cu addition, produced both by continuous and direct-chill (DC) casting techniques. At low temperatures and fast strain rates, for which solute-drag (SD) creep governs deformation, the Cu addition slightly increases tensile ductility at 450 °C but does not otherwise alter deformation behaviors. At high temperatures and slow strain rates, for which grain- boundary-sliding (GBS) creep governs deformation, the Cu addition decreases flow stress and, at 450 °C, improves tensile ductility. A strong temperature dependence for tensile ductility results from the Cu addition; tensile ductility at 500 °C is notably reduced from that at 450 °C. The Cu addition creates platelike particles at grain boundaries, which produce incipient melting and the observed mechanical behavior

Analysis, representation, and prediction of creep transients in Class I alloys

The article of record as published may be found at http://dx.doi.org/10.1016/j.msea.2005.08.085Solute-drag (SD) creep in Class I alloys is characterized by several features. Among these is the presence of “inverse” creep transients, which are unique to these solid-solution alloys and the SD creep mechanism. Creep transients in commercial AA5083 materials under SD creep are analyzed using a model based on a graphical construct previously proposed. It is observed that transient behavior can be represented in a general fashion which predicts the decay in relative transient size as a function of strain. Experimental data for SD creep are presented using the proposed graphical construct to determine the dependence of dislocation glide speed on stress and the dependence of equilibrium mobile dislocation density on stress. It is observed that the high stress exponents of the commercial AA5083 materials under SD creep, relative to low-impurity, binary Al–Mg materials, are primarily the result of an increased dependence of dislocation glide speed on stress.General Motors Corporatio

Failure mechanisms in superplastic AA5083 materials

The mechanisms of tensile failure in four 5083 aluminum sheet materials are evaluated under conditions of interest for superplastic and quick-plastic forming. Two mechanisms are shown to control failure of the AA5083 materials under uniaxial tension at elevated temperatures: cavitation and flow localization (i.e., necking). Conditions for which failure is controlled by cavitation correspond to those under which deformation is primarily by grain-boundary-sliding creep. Conditions for which failure is controlled by flow localization correspond to those under which deformation is primarily by solute- drag creep. A geometric parameter, Q, is used to determine whether final failure is controlled by cavitation or by flow localization. Differences in elongations to failure between the different AA5083 materials at high temperatures and slow strain rates are the result of differences in cavitation behaviors. The rate of cavitation growth with strain is nearly constant between the AA5083 materials for identical testing conditions, but materials with less tensile ductility evidence initial cavitation development at lower strain levels. The rate of cavitation growth with strain is shown to depend on the governing deformation mechanism; grain-boundary-sliding creep produces a faster cavitation growth rate than does solute-drag creep. A correlation is found between the early development of cavitation and the intermetallic particle-size population densities of the AA5083 materials. Fine filaments, oriented along the tensile axis, are observed on fracture surfaces and within surface cavities of specimens deformed primarily under grain-boundary-sliding creep. As deformation transitions to control by solute-drag creep, the density of these filaments dramatically decreases.General Motors Corporatio