Investigation of slip transfer across HCP grain boundaries with application to cold dwell facet fatigue

This paper addresses the role of grain boundary slip transfer and thermally-activated discrete dislocation plasticity in the redistribution of grain boundary stresses during cold dwell fatigue in titanium alloys. Atomistic simulations have been utilised to calculate the grain boundary energies for titanium with respect to the misorientation angles. The grain boundary energies are utilised within a thermally-activated discrete dislocation plasticity model incorporating slip transfer controlled by energetic and grain boundary geometrical criteria. The model predicts the grain size effect on the flow strength in Ti alloys. Cold dwell fatigue behaviour in Ti-6242 alloy is investigated and it is shown that significant stress redistribution from soft to hard grains occurs during the stress dwell, which is observed both for grain boundaries for which slip transfer is permitted and inhibited. However, the grain boundary slip penetration is shown to lead to significantly higher hard-grain basal stresses near the grain boundary after dwell, thus exacerbating the load shedding stress compared to an impenetrable grain boundary. The key property controlling the dwell fatigue response is argued to remain the time constant associated with the thermal activation process for dislocation escape, but the slip penetrability is also important and exacerbates the load shedding. The inclusion of a macrozone does not significantly change the conclusions but does potentially lead to the possibility of a larger initial facet

Discrete dislocation and crystal plasticity analyses of load shedding in polycrystalline titanium alloys

The focus of this paper is the mechanistic basis of the load shedding phenomenon that occurs under the dwell fatigue loading scenario. A systematic study was carried out using a discrete dislocation plasticity (DDP) model to investigate the effect of crystallographic orientations, localised dislocation behaviour and grain combinations on the phenomenon. Rate sensitivity in the model arises from a thermal activation process at low strain rates, which is accounted for by associating a stress- and temperature-dependent release time with obstacles; the activation energy was determined by calibrating an equivalent crystal plasticity model to experimental data. First, the application of Stroh's dislocation pile-up model of crack nucleation to facet fracture was quantitatively assessed using the DDP model. Then a polycrystalline model with grains generated using a controlled Poisson Voronoi tessellation was used to investigate the soft-hard-soft rogue grain combination commonly associated with load shedding. Dislocation density and peak stress at the soft/hard grain boundary increased significantly during the stress dwell period, effects that were enhanced by dislocations escaping from pile-ups at obstacles. The residual stress after dwell fatigue loading was also found to be much higher compared to standard fatigue loading. Taylor (uniform strain) and Sachs (uniform stress) type assumptions in a soft-hard grain combination have been assessed with a simple bicrystal DDP model. Basal slip nucleation in the hard grain was found to be initiated by high stresses generated by strong pile ups in the soft grain, and both basal and pyramidal slip nucleation was observed in the hard grain when the grain boundary orientation aligned with that of an active slip system in the soft grain. The findings of this study give new insight into the mechanisms of load shedding and faceting associated with cold dwell fatigue in Ti alloys used in aircraft engines

Concept Validation for Selective Heating and Press Hardening of Automotive Safety Components with Tailored Properties

© (2014) Trans Tech Publications, Switzerland.A new strategy termed selective heating and press hardening, for hot stamping of boron steel parts with tailored properties is proposed in this paper. Feasibility studies were carried out through a specially designed experimental programme. The main aim was to validate the strategy and demonstrate its potential for structural optimisation. In the work, a lab-scale demonstrator part was designed, and relevant manufacturing and property-assessment processes were defined. A heating technique and selective-heating rigs were designed to enable certain microstructural distributions in blanks to be obtained. A hot stamping tool set was designed for forming and quenching the parts. Demonstrator parts of full martensite phase, full initial phase, and differentially graded microstructures have been formed with high dimensional quality. Hardness testing and three point bending tests were conducted to assess the microstructure distribution and load bearing performance of the as-formed parts, respectively. The feasibility of the concept has been validated by the testing results

An Investigation, Using Standard Experimental Techniques, to Determine FLCs at Elevated Temperature for Aluminium Alloys

An experimental procedure has been developed for the determination of FLCs at elevated temperatures. The GOM ARGUS system was employed for measuring surface strain based on pre-applied grids (pattern), and limit strains were determined according to the ISO 12004-2:2008 standard. Forming limit curves (FLCs) have been determined for AA5754 under warm forming conditions in an isothermal environment. The tests were carried out at various temperatures up to 300oC and forming speeds ranging from 5 – 300 mm s-1 . Results reveal the significant effect of both temperature and forming speed on FLCs of AA5754. Formability increases with increasing temperature above 200oC. Formability also increases with decreasing speed. The presented FLC results show that the best formability exists at low forming speed and the high temperature end of the warm forming range

A new hardness formula incorporating the effect of source density on indentation response: a discrete dislocation plasticity analysis

Planar discrete dislocation plasticity (DDP) calculations that simulate thin single crystal films bonded to a rigid substrate indented by a rigid wedge are performed for different values of film thickness and dislocation source density. As in prior studies, an indentation size effect (ISE) is observed when indentation depth is sufficiently small relative to the film thickness. The dependence of the ISE on dislocation source density is quantified in this study, and a modified form of the scaling law for the dependence of hardness on indentation depth, first derived by Nix and Gao, is proposed, which is valid over the entire range of indentation depths and correlates the length scale parameter with the average dislocation source spacing. Nanoindentation experimental data from the literature are fitted using this formula, which further verifies the proposed scaling of indentation pressure on dislocation source density

A virtual crystal plasticity simulation tool for micro-forming

AbstractThe trend of increasing miniaturization of varied products and devices with a wide range of applications necessitates the forming of metallic parts with dimensions at the micron scale. In micro-forming, the stress and deformation are highly anisotropic. Hence, conventional macro-mechanics models fail to capture the important features, such as necking and bending resulting from strain localization. In this paper, a virtual integrated micro-mechanics simulation tool is presented, that was developed within the framework of Crystal Plasticity (CP) theory. With this tool, a polycrystalline Finite Element (FE) model was produced by introducing grain size, orientations and distribution patterns using VGRAIN software. ABAQUS software was used and the CP constitutive equations were implemented through a user-defined material subroutine, VUMAT. Typical micro-forming processes simulated include tension, extrusion and hydro-forming to demonstrate the effectiveness of the integrated simulation system. Finally, a map is proposed that establishes bounds of appropriate usage for different modeling techniques, namely a macromechanics plasticity model and a micro-mechanics crystal plasticity model, which will be useful to engineers in the metal forming industry in choosing suitable simulation tools

Solution heat treatment, forming and in-die quenching of a commercial sheet magnesium alloy into a complex-shaped component: experimentation and FE analysis

Interest in lightweight materials, particularly magnesium alloys, has increased significantly with rising efficiency requirements in the automotive sector. Magnesium is the lightest available structural metal, with a density approximately 35% lower than that of aluminium. The potential is great for magnesium to become a primary material used in future low carbon vehicle structures; however, there are significant obstacles, namely low ductility and formability, particularly at room temperature. The aim of this work is to present the feasibility of using the solution Heat treatment, Forming, and in-die Quenching (HFQ) process to produce complex shapes from a sheet magnesium alloy, and to use the results to verify a simulation of the process developed using commercial FE software. Uniaxial tensile tests were initially conducted to establish the optimum parameters for forming the part. Stamping trials were then carried out using these parameters, and a simulation set up modelling the forming operation. It was shown that the HFQ process could be used to form a successful component from this alloy, and that a good match was achieved between the results of the forming experiments and the simulation.The authors gratefully acknowledge the support from the EPSRC (Grant Ref: EP/I038616/1) for TARF-LCV: Towards Affordable, Closed-Loop Recyclable Future Low Carbon Vehicle Structures

Experimental characterisation of the effects of thermal conditions on austenite formation for hot stamping of boron steel

The formation of austenite in manganese-boron steels during selective heat treatment has great significance in the application of innovative hot stamping processes. Heat treatment tests were designed according to the thermal cycle of industrial heating and hot stamping processes and were conducted on a Gleeble 3800 thermomechanical testing system. Specimens were subjected to non-isothermal (heating rates: 1 K/s–25 K/s) and isothermal (soaking temperatures: 1023 K–1173K) temperature profiles. A high-resolution dilatometer was employed to detect the dimensional change of the specimens associated with austenitization. The dilatometric measurement was quantitatively related to the volume fraction of austenite. By analysing the evolution curves of austenite fraction, the effects of heating rate and temperature on the progress of austenite formation under both non-isothermal and isothermal conditions were investigated and characterised, improving the current understanding of the mechanisms that control austenite formation in manganese-boron steels