Texture evolution via combined slip and deformation twinning in rolled silver-copper cast eutectic nanocomposite

In this work, a silver-copper (Ag-Cu) nanocomposite with 200 nm bilayer thickness and eutectic composition was rolled at room temperature and 200 °C to nominal reductions of 75% and higher. Initially the material had a random texture and {1 1 1} bi-metal interface plane. X-ray diffraction measurements show that the Ag and Cu phases developed the same brass-type (or ‘alloy-type’) rolling texture regardless of rolling reduction and temperature. Transmission electron microscopy analyses of the nanostructures before and after rolling suggest that adjoining Ag and Cu layers maintained a cube-on-cube relationship but the interface plane changed after rolling. Polycrystal plasticity simulations accounting for plastic slip and deformation twinning in each phase were carried out to explore many possible causes for the brass-type texture development: twinning via a volume effect or barrier effect, Shockley partial slip, and confined layer slip. The results suggest that the observed texture evolution may be due to profuse twinning within both phases. Maintaining the cube-on-cube relationship would then imply that neighboring Ag and Cu crystals twinned by the same variant and on a twin plane non-parallel to the original interface plane. Explanations for this unusual possibility for Cu are provided at the end based on the properties of the Ag-Cu interface.     

A dislocation-based constitutive law for pure Zr including temperature effects

In this work, a single crystal constitutive law for multiple slip and twinning modes in single phase hcp materials is developed. For each slip mode, a dislocation population is evolved explicitly as a function of temperature and strain rate through thermally-activated recovery and debris formation and the associated hardening includes stage IV. A stress-based hardening law for twin activation accounts for temperature effects through its interaction with slip dislocations. For model validation against macroscopic measurement, this single crystal law is implemented into a visco-plastic-self-consistent (VPSC) polycrystal model which accounts for texture evolution and contains a subgrain micromechanical model for twin reorientation and morphology. Slip and twinning dislocations interact with the twin boundaries through a directional Hall–Petch mechanism. The model is adjusted to predict the plastic anisotropy of clock-rolled pure Zr for three different deformation paths and at four temperatures ranging from 76 K to 450 K (at a quasi-static rate of 10⁻³ 1/s). The model captures the transition from slip-dominated to twinning-dominated deformation as temperature decreases, and identifies microstructural mechanisms, such as twin nucleation and twin–slip interactions, where future characterization is needed.     

A perspective on trends in multiscale plasticity

Research trends in metal plasticity over the past 25 years are briefly reviewed. The myriad of length scales at which phenomena involving microstructure rearrangement during plastic flow is discussed, along with key challenges. Contributions of the author’s group over the past 30 years are summarized in this context, focusing on the statistical nature of microstructure evolution and emergent multiscale behavior associated with metal plasticity, current trends and models for length scale effects, multiscale kinematics, the role of grain boundaries, and the distinction of the roles of concurrent and hierarchical multiscale modeling in the context of materials design.     

Size effects on the martensitic phase transformation of NiTi nanograins

The analysis of nanocrystalline NiTi by transmission electron microscopy (TEM) shows that the martensitic transformation proceeds by the formation of atomic-scale twins. Grains of a size less than about 50 nm do not transform to martensite even upon large undercooling. A systematic investigation of these phenomena was carried out elucidating the influence of the grain size on the energy barrier of the transformation. Based on the experiment, nanograins were modeled as spherical inclusions containing (0 0 1) compound twinned martensite. Decomposition of the transformation strains of the inclusions into a shear eigenstrain and a normal eigenstrain facilitates the analytical calculation of shear and normal strain energies in dependence of grain size, twin layer width and elastic properties. Stresses were computed analytically for special cases, otherwise numerically. The shear stresses that alternate from twin layer to twin layer are concentrated at the grain boundaries causing a contribution to the strain energy scaling with the surface area of the inclusion, whereas the strain energy induced by the normal components of the transformation strain and the temperature dependent chemical free energy scale with the volume of the inclusion. In the nanograins these different energy contributions were calculated which allow to predict a critical grain size below which the martensitic transformation becomes unlikely. Finally, the experimental result of the atomic-scale twinning can be explained by analytical calculations that account for the transformation-opposing contributions of the shear strain and the twin boundary energy of the twin-banded morphology of martensitic nanograins.     

Experimental study on axial development of liquid film in vertical upward annular two-phase flow

Accurate measurements of the interfacial wave structure of upward annular two-phase flow in a vertical pipe were performed using a laser focus displacement meter (LFD). The purpose of this study was to clarify the effectiveness of the LFD for obtaining detailed information on the interfacial displacement of a liquid film in annular two-phase flow and to investigate the effect of axial distance from the air–water inlet on the phenomena. Adiabatic upward annular air–water flow experiments were conducted using a 3 m long, 11 mm ID pipe. Measurements of interfacial waves were conducted at 21 axial locations, spaced 110 mm apart in the pipe. The axial distances from the inlet (z) normalized by the pipe diameter (D) varied over z/D = 50–250. Data were collected for predetermined gas and liquid flow conditions and for Reynolds numbers ranging from Re_G = 31,800 to 98,300 for the gas phase and Re_L = 1050 to 9430 for the liquid phase. Using the LFD, we obtained such local properties as the minimum thickness, maximum thickness, and passing frequency of the waves. The maximum film thickness and passing frequency of disturbance waves decreased gradually, with some oscillations, as flow developed. The flow development, i.e., decreasing film thickness and passing frequency, persisted until the end of the pipe, which means that the flow might never reach the fully developed state. The minimum film thickness decreased with flow development and with increasing gas flow rate. These results are discussed, taking into account the buffer layer calculated from Karman’s three-layer model. A correlation is proposed between the minimum film thickness obtained in relation to the interfacial shear stress and the Reynolds number of the liquid.     

Macro-to-microchannel transition in two-phase flow: Part 1 - Two-phase flow patterns and film thickness measurements

The classification of macroscale, mesoscale and microscale channels with respect to two-phase processes is still an open question. The main objective of this study focuses on investigating the macro-to-microscale transition during flow boiling in small scale channels of three different sizes with three different refrigerants over a range of saturation conditions to investigate the effects of channel confinement on two-phase flow patterns and liquid film stratification in a single circular horizontal channel (Part 2 covers the flow boiling heat transfer and critical heat flux). This paper presents the experimental two-phase flow pattern transition data together with a top/bottom liquid film thickness comparison for refrigerants R134a, R236fa and R245fa during flow boiling in small channels of 1.03, 2.20 and 3.04 mm diameter. Based on this work, an improved flow pattern map has been proposed by determining the flow patterns transitions existing under different conditions including the transition to macroscale slug/plug flow at a confinement number of Co ≈ 0.3-0.4. From the top/bottom liquid film thickness comparison results, it was observed that the gravity forces are fully suppressed and overcome by the surface tension and shear forces when the confinement number approaches 1, Co ≈ 1. Thus, as a new approximate rule, the lower threshold of macroscale flow is Co = 0.3-0.4 while the upper threshold of symmetric microscale flow is Co ≈ 1 with a transition (or mesoscale) region in-between.     

Size effects in indentation response of thin films at the nanoscale: A molecular dynamics study

The indentation response of Ni thin films of thicknesses in the nanoscale was studied using molecular dynamics simulations with embedded atom method (EAM) interatomic potentials. A series of simulations were performed in films in the [1 1 1] orientation with thicknesses varying from 4 to 12.8 nm. The study included both single crystal films and films containing low angle grain boundaries perpendicular to the film surface. The simulation results for single crystal films show that as film thickness decreases larger forces are required for similar indentation depths but the contact stress necessary to emit the first dislocation under the indenter is nearly independent of film thickness. The low angle grain boundaries can act as dislocation sources under indentation. The mechanism of preferred dislocation emission from these boundaries operates at stresses that are lower as the film thickness increases and is not active for the thinnest films tested. These results are interpreted in terms of a simple model.     

Grain size,strain rate,and temperature dependence of flow stress in ultra-fine grained and nanocrystalline Cu and Al: Synthesis,experiment, and constitutive modeling

For the first time, high quality bulk nanocrystalline (nc) fcc metals, with least amounts of imperfections, exhibiting high strength and ductility at room and different temperatures, under quasi-static and dynamic types of loading, were prepared and a comprehensive study on their post-yield mechanical properties was performed. This investigation included study of the effect of temperature on stress–strain responses of mechanically milled bulk nc Cu and Al. The samples after preparation through mechanical milling and consolidation processes were subjected to uniaxial compressive loading at quasi-static and dynamic strain rates of 10⁻² s⁻¹ and 1840–3105 s⁻¹, respectively, at temperatures ranging from 223 to 523 K. In both materials strong dependency of flow stress to temperature was observed; this dependency was rather more pronounced when the materials were tested at the quasi-static strain rate. Further, a new grain size and temperature dependent viscoplastic phenomenological constitutive equation, Khan–Liang–Farrokh (KLF) model was developed based on the Khan–Huang–Liang (KHL) constitutive equation. The model was featured to correlate different characteristic behaviors of polycrystalline materials in the plastic regime, as the result of grain refinement. In addition, the viscoplastic responses of bulk Cu and Al of different grain sizes (from sub-micron to nanometer range), and those from bulk nc Cu and Al at different strain rates (quasi-static to dynamic), recently published (21 and 22), were simulated using the newly developed equation. The results confirmed reasonable capability of the developed model to correlate a wide spectrum of the viscoplastic responses of these fcc metals.     

Heat transfer to air–water annular flow in a horizontal pipe

Two-phase air–water flow and heat transfer in a 25 mm internal diameter horizontal pipe were investigated experimentally. The water superficial velocity varied from 24.2 m/s to 41.5 m/s and the air superficial velocity varied from 0.02 m/s to 0.09 m/s. The aim of the study was to determine the heat transfer coefficient and its connection to flow pattern and liquid film thickness. The flow patterns were visualized using a high speed video camera, and the film thickness was measured by the conductive tomography technique. The heat transfer coefficient was calculated from the temperature measurements using the infrared thermography method. It was found that the heat transfer coefficient at the bottom of the pipe is up to three times higher than that at the top, and becomes more uniform around the pipe for higher air flow-rates. Correlations on local and average Nusselt number were obtained and compared to results reported in the literature. The behavior of local heat transfer coefficient was analyzed and the role of film thickness and flow pattern was clarified.     

Critical friction factor modeling of horizontal annular base film thickness

Measurements of liquid base film thickness distribution have been obtained for 206 horizontal annular two-phase (air–water) flow conditions in 8.8 mm, 15.1 mm, and 26.3 mm ID tubes. It is found that the trends in base film thickness measurement do not match trends in the literature for average film thickness, which considers waves and base film together. An iterative critical friction factor model is used to model circumferentially-averaged base film thickness; an explicit, empirical correlation is also provided. Asymmetry is well-correlated by a modified Froude number based on the correlated base film thickness and the gas mass flux. The iterative model is also extended to estimate the critical film flow rate.     

Analysis of heterogeneous deformation and dislocation dynamics in single crystal micropillars under compression

The size dependent deformation of Cu single crystal micropillars with thickness ranging from 0.2 to 2.5 μm subjected to uniaxial compression is investigated using a Multi-scale Dislocation Dynamics Plasticity (MDDP) approach. MDDP is a hybrid elasto-viscoplastic simulation model which couples discrete dislocation dynamics at the micro-scale (software micro3d) with the macroscopic plastic deformation. Our results show that the deformation field in these micropillars is heterogeneous from the onset of plastic flow and is confined to few deformation bands, leading to the formation of ledges and stress concentrations at the surface of the specimen. Furthermore, the simulation yields a serrated stress–strain behavior consisting of discrete strain bursts that correlates well with experimental observations. The intermittent operation and stagnation of discrete dislocation arms is identified as the prominent mechanism that causes heterogeneous deformation and results in the observed macroscopic strain bursts. We show that the critical stress to bow an average maximum dislocation arm, whose length changes during deformation due to pinning events, is responsible for the observed size dependent response of the single crystals. We also reveal that hardening rates, similar to that shown experimentally, occur under relatively constant dislocation densities and are linked to dislocation stagnation due to the formation of entangled dislocation configuration and pinning sites.     

Cyclic behavior of extruded magnesium: Experimental, microstructural and numerical approach

The present study aims at determining the influence of cyclic straining on the behavior of pure extruded magnesium. For this purpose, tensile, compressive and cyclic tests are performed (small plastic strains are applied (Δε^p/2 = 0.1% and 0.4%). Deformation mechanisms (slip and twin systems) have been observed by TEM and the different critical resolved shear stress (CRSS) have been determined. Based on microscopic observations, a crystal-plasticity-based constitutive model has been developed. The asymmetry between tensile and compressive loadings mainly results from the activation of hard slip systems in tension (such as 〈a〉 pyramidal and prismatic and 〈c + a〉 pyramidal glides) and twinning in compression. It is shown that basal slip is very easy to activate even for small Schmid factors. Numerical simulations reveal that untwinning in tension subsequent to compression must be considered to correctly fit the experimental S-shaped hysteresis curves. TEM observations indicate also intense secondary slips or twins inside the mother twins under cyclic conditions, so that twinning in compression and dislocation glide in tension are affected by cycling. The polycrystalline model allows to predict slip activities and twin volume fraction evolutions.     

Anisotropic responses, constitutive modeling and the effects of strain-rate and temperature on the formability of an aluminum alloy

Finite deformation anisotropic responses of AA5182-O, over a wide range of strain-rates (10⁻⁴ to 10⁰ s⁻¹) and temperatures (293-473 K) are presented. The plastic anisotropy parameters were experimentally determined from tensile experiments using specimens from sheet material. Using the experimental results under plane stress conditions, the anisotropy coefficients for Barlat’s yield function (YLD96) were calculated at different strain-rates and temperatures. The correlations obtained from YLD96 are in good agreement with the observed experimental results. The strain-rate sensitivity of AA5182-O alloy changed from negative at 293 K to positive at 473 K. Khan-Huang-Liang (KHL) constitutive model is shown to correlate the observed strain-rate and temperature dependent responses reasonably well. The material parameters were obtained from the experimental responses along the rolling direction (RD) of the sheet. Marciniak and Kuckzinsky (M-K) theory was used to obtain the theoretical strain and stress-based forming limit curves (FLCs) at different strain-rates and temperatures. The experimental result from the published literature is compared with the FLCs from the current study.     

Counter-current gas–liquid flow in a vertical narrow channel—Liquid film characteristics and flooding phenomena

Results are reported of an experimental investigation of gas–liquid counter-current flow in a vertical rectangular channel with 10 mm gap, at rather short distances from liquid entry. Flooding experiments are carried out using air and various liquids (i.e., water, 1.5% and 2.5% aqueous butanol solutions) at liquid Reynolds numbers Re_L < 350. Visual observations and fast recordings suggest that the onset of flooding at low Re_L (<250) is associated with liquid entrainment from isolated waves, whereas “local bridging” is dominant at the higher Re_L examined in this study. Significant reduction of flooding velocities is observed with decreasing interfacial tension, as expected. Instantaneous film thickness measurements show that under conditions approaching flooding, a sharp increase of the mean film thickness, of mean wave amplitude and of the corresponding RMS values takes place. Film thickness power spectra provide evidence that by increasing gas flow the wave structure is significantly affected; e.g., the dominant wave frequency is drastically reduced. These data are complemented by similar statistical information from instantaneous wall shear stress measurements made with an electrochemical technique. Power spectra of film thickness and of shear stress display similarities indicative of the strong effect of waves on wall stress; additional evidence of the drastic changes in the liquid flow field near the wall due to the imposed gas flow, even at conditions below flooding, is provided by the RMS values of the wall stress. A simple model is presented for predicting the mean film thickness and mean wall shear stress under counter-current gas–liquid flow, below critical flooding velocities.     

Experimental study on oil–water flow in horizontal and slightly inclined pipes

Oil–water two-phase flow experiments were conducted in a 15 m long, 8.28 cm diameter, inclinable steel pipe using mineral oil (density of 830 kg/m³ and viscosity of 7.5 mPa s) and brine (density of 1060 kg/m³ and viscosity of 0.8 mPa s). Steady-state data on flow patterns, two-phase pressure gradient and holdup were obtained over the entire range of flow rates for pipe inclinations of −5°, −2°, −1.5°, 0°, 1°, 2° and 5°. The characterization of flow patterns and identification of their boundaries was achieved via observation of recorded movies and by analysis of the relative deviation from the homogeneous behavior. A stratified wavy flow pattern with no mixing at the interface was identified in downward and upward flow. Two gamma-ray densitometers allowed for accurate measurement of the absolute in situ volumetric fraction (holdup) of each phase for all flow patterns. Extensive results of holdup and two-phase pressure gradient as a function of the superficial velocities, flow pattern and inclinations are reported. The new experimental data are compared with results of a flow pattern dependent prediction model, which uses the area-averaged steady-state two-fluid model for stratified flow and the homogeneous model for dispersed flow. Prediction accuracies for oil/water holdups and pressure gradients are presented as function of pipe inclination for all flow patterns observed. There is scope for improvement for in particular dual-continuous flow patterns.     

A microbeam bending method for studying stress-strain relations for metal thin films on silicon substrates

We have developed a microbeam bending technique for determining elastic-plastic, stress-strain relations for thin metal films on silicon substrates. The method is similar to previous microbeam bending techniques, except that triangular silicon microbeams are used in place of rectangular beams. The triangular beam has the advantage that the entire film on the top surface of the beam is subjected to a uniform state of plane strain as the beam is deflected, unlike the standard rectangular geometry where the bending is concentrated at the support. To extract the average stress-strain relations for the film, we present a method of analysis that requires computation of the neutral plane for bending, which changes as the film deforms plastically. This method can be used to determine the elastic-plastic properties of thin metal films on silicon substrates up to strains of about 1%.Utilizing this technique, both yielding and strain hardening of Cu thin films on silicon substrates have been investigated. Copper films with dual crystallographic textures and different grain sizes, as well as others with strong 〈1 1 1〉 textures have been studied. Three strongly textured 〈1 1 1〉 films were studied to examine the effect of film thickness on the deformation properties of the film. These films show very high rates of work hardening, and an increase in the yield stress and work hardening rate with decreasing film thickness, consistent with current dislocation models.     

Relations between twin and slip in parent lattice due to kinematic compatibility at interfaces

The relationships between a slip system in the parent lattice and its transform by twinning shear are considered in regards to tangential continuity conditions on the plastic distortion rate at twin/parent interface. These conditions are required at coherent interfaces like twin boundaries, which can be assigned zero surface-dislocation content. For two adjacent crystals undergoing single slip, relations between plastic slip rates, slip directions and glide planes are accordingly deduced. The fulfillment of these conditions is investigated in hexagonal lattices at the onset of twinning in a single slip deforming parent crystal. It is found that combinations of slip system and twin variant verifying the tangential continuity of the plastic distortion rate always exist. In all cases, the Burgers vector belongs to the interface. Certain twin modes are only admissible when slip occurs along an 〈a〉 direction of the hexagonal lattice, and some others only with a 〈c + a〉 slip. These predictions are in agreement with EBSD orientation measurements in commercially pure Ti sheets after plane strain compression.     

Discrete element simulation of shock wave propagation in polycrystalline copper

The implementation of the characteristic of compressive plasticity into the Discrete Element Code, DM2, while maintaining its quasi-molecular scheme, is described. The code is used to simulate the shock compression of polycrystalline copper at 3.35 and 11.0 GPa. The model polycrystal has a normal distribution of grain sizes, with mean diameter 14 μm, and three distinct grain orientations are permitted with respect to the shock direction; 〈1 0 0〉, 〈1 1 0〉, and 〈1 1 1〉. Particle velocity dispersion (PVD) is present in the shock-induced flow, attaining its maximum magnitude at the plastic wave rise. PVD normalised to the average particle velocity of and are yielded for the 3.35 and 11.0 GPa shocks, respectively, and are of the same order as those seen in the experiment. Non-planar elastic and plastic wave fronts are present, the distribution in shock front position increasing with propagation distance. The rate of increase of the spread in shock front positions is found to be significantly smaller than that seen in probabilistic calculations on nickel polycrystals, and this difference is attributed, in the main, to grain interaction. Reflections at free surfaces yield a region of tension near to the target free surface. Due to the dispersive nature of the shock particle velocity and the non-planarity of the shock front, the tensile pressure is distributed. This may have implications for the spall strength, which are discussed. Simulations reveal a transient shear stress distribution behind the shock front. Such a distribution agrees with that put forward by Lipkin and Asay to explain the quasi-elastic reloading phenomenon. Simulation of reloading shocks show that the shear stress distribution can give rise to quasi-elastic reloading on the grain scale.     

Dislocation nucleation in Σ3 asymmetric tilt grain boundaries

Atomistic simulations were used to investigate dislocation nucleation from Σ3 asymmetric (inclined) tilt grain boundaries under uniaxial tension applied perpendicular to the boundary. Molecular dynamics was employed based on embedded atom method potentials for Cu and Al at 10 K and 300 K. Results include the grain boundary structure and energy, along with mechanical properties and mechanisms associated with dislocation nucleation from these Σ3 boundaries. The stress and work required for dislocation nucleation were calculated along with elastic stiffness of the bicrystal configurations, exploring the change in response as a function of inclination angle. Analyses of dislocation nucleation mechanisms for asymmetric Σ3 boundaries in Cu show that dislocation nucleation is preceded by dislocation dissociation from the boundary. Then, dislocations preferentially nucleate in only one crystal on the maximum Schmid factor slip plane(s) for that crystal. However, this crystal is not simply predicted based on either the Schmid or non-Schmid factors. The synthesis of these results provides a better understanding of the dislocation nucleation process in these faceted, dissociated grain boundaries.     

Cold rolling mill process: a numerical procedure for industrial applications

The paper proposes a model for a cold rolling mill process in the full-film regime that uses lubricant emulsion sprayed on at the entrance of the strip. The aim of the model is to forecast the reduction of strip thickness versus the flow rate of lubricant given the other operation parameters. The model includes strip plastic deformation, lubricant flow and lubricant viscosity depending on pressure. The mathematical problem is a free boundary one and a numerical procedure, applied to an industrial plant, is presented with some results.