Thermo-micro-mechanical simulation of bulk metal forming processes

The newly proposed microstructural constitutive model for polycrystal viscoplasticity in cold and warm regimes (Motaman and Prahl, 2019), is implemented as a microstructural solver via user-defined material subroutine in a finite element (FE) software. Addition of the microstructural solver to the default thermal and mechanical solvers of a standard FE package enabled coupled thermo-micro-mechanical or thermal-microstructural-mechanical (TMM) simulation of cold and warm bulk metal forming processes. The microstructural solver, which incrementally calculates the evolution of microstructural state variables (MSVs) and their correlation to the thermal and mechanical variables, is implemented based on the constitutive theory of isotropic hypoelasto-viscoplastic (HEVP) finite (large) strain/deformation. The numerical integration and algorithmic procedure of the FE implementation are explained in detail. Then, the viability of this approach is shown for (TMM-) FE simulation of an industrial multistep warm forging

Modeling of grain boundary dynamics using amplitude equations

We discuss the modelling of grain boundary dynamics within an amplitude equations description, which is derived from classical density functional theory or the phase field crystal model. The relation between the conditions for periodicity of the system and coincidence site lattices at grain boundaries is investigated. Within the amplitude equations framework we recover predictions of the geometrical model by Cahn and Taylor for coupled grain boundary motion, and find both $\langle100\rangle$ and $\langle110\rangle$ coupling. No spontaneous transition between these modes occurs due to restrictions related to the rotational invariance of the amplitude equations. Grain rotation due to coupled motion is also in agreement with theoretical predictions. Whereas linear elasticity is correctly captured by the amplitude equations model, open questions remain for the case of nonlinear deformations.Comment: 21 pages. We extended the discussion on the geometrical nonlinearities in Section

Characterization and Modeling of Failure Initiation in Bainite‐Aided DP Steel

Peer Reviewedhttp://deepblue.lib.umich.edu/bitstream/2027.42/109564/1/adem201300556.pd

On the spheroidized carbide dissolution and elemental partitioning in a high carbon bearing steel 100Cr6

We report on the characterization of high carbon bearing steel 100Cr6 using electron microscopy and atom probe tomography in combination with multi-component diffusion simulations (DICTRA). Scanning electron micrographs show that around 14 vol.% spheroidized carbides are formed during soft annealing and only 3 vol.% remain after dissolution into the austenitic matrix by austenitization at 1123 K (850 {\deg}C) for 300 s. The spheroidized particles are identified as (Fe, Cr)3C by transmission electron microscopy. Atom probe analyses reveal the redistribution and partitioning behaviors of elements, i.e. C, Si, Mn, Cr, Fe in both, the spheroidized carbides and the bainitic matrix in the sample isothermally heat-treated at 773 K (500 {\deg}C) after austenitization. A homogeneous distribution of C and gradual gradient of Cr was detected within the spheroidized carbides. Due to its limited diffusivity in (Fe, Cr)3C, Cr exhibits a maximum concentration at the surface of spheroidized carbides (16 at.%) and decreases gradually from surface towards the core down to a level of about 2 at.%. The atom probe results also indicate that the partially dissolved spheroidized carbides during austenitization may serve as nucleation sites for intermediate temperature cementite within bainite, which results in a relatively softer surface and harder core in spheroidized particles. This microstructure may contribute to the good wear resistance and fatigue propertie

Development of Guidelines for the Groove Rolling of Magnesium Alloys Which Contain Calcium

The topic of climate protection and, for example, the resulting need for a reduction in the use of fossil fuels, is a major focus of research. Particular interest is taken in the substitution of traditional metals such as steel with lightweight materials like aluminium and magnesium alloys in the automotive and generally in the transportation sector. Due to the hexagonal crystal structure of magnesium, the processing of its alloys contains some almost unique challenges. By alloying calcium, for example in ZAX-alloys – containing zinc, aluminium and calcium – the formability at room temperature is improved through a less pronounced texture with a basal pole split. [2] To join the replaced components in the cars, welding can be used. This process profits from procedure where base and weld material are of similar compositions. For welding, and for wire-based additive manufacturing too, wires with a diameter of approximately 1 – 1.6 mm are required, which can only be produced through drawing. The production for the preliminary products can be achieved through either extrusion or groove rolling. For the latter there is a lack of fundamental empirical experience and research results that are required for a successful application and implementation in the industry. The extrusion process is more established but groove rolling has the potential to produce larger quantities in the same time and has the added advantage of a greater grain refinement

Microstructure and Texture evolution during foil rolling of an extruded WE43 alloy

WE43 magnesium foils (thickness ≤ 200 μm) were successfully produced via hot rolling. The initially extruded material was heat treated at 450 °C for 2 h to achieve a more homogenous microstructure. Afterwards the sheets were hot rolled at 480 °C in two to five rolling passes to achieve a thickness less than 200 μm and finally heat treated (T5 and T6 heat treatment). Microstructural und texture evolution after foil rolling and the final heat treatment were investigated and the resulting mechanical properties were also evaluated. Therefore, the samples were quenched directly after foil rolling and the final heat treatment. The foil rolling led depending on the number of the rolling passes either to a deformation microstructure (two and three passes) or globular grains (four and five passes)

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