Multiscale characterisation of the mechanical properties of austenitic stainless steel joints

A multiscale investigation was pursued in order to obtain the strain distribution and evolution during tensile testing both at the macro- and micro-scale for a diffusion bonded 316L stainless steel. The samples were designed for the purpose to demonstrate that the bond line properties were equal or better than the parent material in a sample geometry that was extracted from a larger component. The macroscopic stress-strain curves were coupled to the strain distributions using a camera-based 2D – Digital Image Correlation system. Results showed significant amount of plastic deformation predominantly concentrated in shear bands which were extended over a large region, crossing through the joint area. Yet it was not possible to be certain whether the joint has shown significant plastic deformation. In order to obtain the joints’ mechanical response in more detail, in situ micromechanical testing was conducted in the SEM chamber that allowed areas of 1x1 mm2 and 50x50 mm2 to be investigated. The size of the welded region was rather small to be accurately captured from the camera based DIC system. Therefore a microscale investigation was pursued where the samples were tested within an SEM chamber. Low magnification SEM imaging was utilised in order to cover a viewing area of 1 mm×1 mm while high magnification SEM imaging was employed to provide evidence of the occurrence of plastic deformation within the joint, at an area of just 50 μm×50 μm. The strain evolution over the microstructural level, within the joint and at the base material was obtained. The local strains were highly non-homogeneous through the whole test. Final failure occurred approximately 0.2 mm away from the joint. Large local strains were measured within the joint region, while SEM imaging showed that plastic deformation occurs via the formation of strong slip bands, followed by the activation of additional slip systems upon further plastic deformation which end up in additional slip bands to form on the surface. Plastic deformation occurred by slip and twinning mechanisms. Upon necking, significant out of plane deformations and slip deformation mechanisms were observed which suggested that plastic deformation was also happening at the last stages of damage evolution for the specific alloy. This was also evident from the large difference between the 600 MPa UTS stress value and the low stress values before final failure (which in many cases was below 30 MPa)

Failure mechanisms in DP600 steel: Initiation, evolution and fracture

Local deformation and damage mechanisms have been studied for a commercial DP600 steel using in-situ tensile testing inside a scanning electron microscope (SEM) in combination with Digital Image Correlation (DIC). Different gauge geometries have been used to study damage evolution processes during tensile testing up to final failure. Strain distributions have been measured within the ferrite and martensite phases, together with the corresponding strain values for identified damage initiation mechanisms. According to the strain maps, large plastic deformation with strain values as large as 4.5 have been measured within the ferrite phase. Severe deformation localization and slip band formation were observed within the ferrite grains. The DIC results show that martensite in the studied material is plastically deformable with a heterogeneous strain distribution within the islands with values of up to 0.9 close to the phase boundaries. Failure of the martensite islands occurs mostly due to micro-crack initiation at the boundaries with the ferrite followed by crack propagation towards the centre of the islands. As for the ferrite matrix, it is found that its interface with the martensite is strong and cohesive. Localized damage in the matrix occurs by sub-micron void formation within the ferrite adjacent to the interface as opposed to the separation along the phase boundary itself or in the central regions of the ferrite grains A mechanism has been proposed to explain the deformation and damage evolution in the microstructure of the studied DP600 steel up to the final fracture

Stability of martensite with pulsed electric current in dual-phase steels

Softening frequently occurs in dual-phase steels under isothermal tempering of martensite. Recently, non-isothermal tempering is implemented to decrease the softening process in dual-phase steels. Here, we have discovered using high power electropulsing treatment can significantly enhance the strengthening effects via the formation of ultrafine-grained ferrite with nano-cementite particles in tempered martensitic-ferritic steels. To the best our knowledge, electropulsing treatment is a proper candidate to retard even to recovery the softening problems in the tempering of martensite in comparison with other isothermal and non-isothermal tempering methods

Effect of Weld Schedule on the Residual Stress Distribution of Boron Steel Spot Welds

Press-hardened boron steel has been utilized in anti-intrusion systems in automobiles, providing high strength and weight-saving potential through gage reduction. Boron steel spot welds exhibit a soft heat-affected zone which is surrounded by a hard nugget and outlying base material. This soft zone reduces the strength of the weld and makes it susceptible to failure. Additionally, different welding regimes lead to significantly different hardness distributions, making failure prediction difficult. Boron steel sheets, welded with fixed and adaptive schedules, were characterized. These are the first experimentally determined residual stress distributions for boron steel resistance spot welds which have been reported. Residual strains were measured using neutron diffraction, and the hardness distributions were measured on the same welds. Additionally, similar measurements were performed on spot welded DP600 steel as a reference material. A correspondence between residual stress and hardness profiles was observed for all welds. A significant difference in material properties was observed between the fixed schedule and adaptively welded boron steel samples, which could potentially lead to a difference in failure loads between the two boron steel welds

Characterization of Loading Responses and Failure Loci of a Boron Steel Spot Weld

Boron steel, classed as an ultra high-strength steel (UHSS), has been utilized in anti-intrusion systems in automobiles, providing high strength and weight-saving potential through gage reduction. UHSS spot welds exhibit unique hardness distributions, with a hard nugget and outlying base material, but with a soft heat-affected zone in-between these regions. This soft zone reduces the strength of the weld and makes it susceptible to failure. Due to the interaction of various weld zones that occurs during loading, there is a need to characterize the loading response of the weld for accurate failure predictions. The loading response of certain weld zones, as well as failure loci, was obtained through physical simulation of the welding process. The results showed a significant difference in mechanical behavior through the weld length. An important result is that instrumented indentation was shown to be a valid, quantitative method for verifying the accuracy with which weld microstructure has been recreated with regard to the target weld microstructure