面向增材制造的熔池凝固组织演变的相场研究

激光增材制造(laser additive manufacturing, LAM)技术极适合复杂整体构件的近净成形和高附值损伤件的快速修复. 然而, 激光增材制造熔池内部复杂的动态凝固过程显著影响成形件的终态组织, 进而制约其服役性能. 本文针对激光直接能量沉积(direct energy deposition by laser, DED-L) Inconel 718过程, 构建宏观传热传质与多相场耦合的多尺度数学模型, 解决了熔池宏?微观温度场的直接耦合, 并基于MPI并行程序设计实现了熔池二维的全域定量模拟, 研究了凝固过程中的晶粒演变过程. 结果表明, 模拟的熔池尺寸、凝固界面与实验结果吻合较好. 熔池凝固界面形态和晶体择优取向是影响晶粒演变的重要因素. 在熔池横截面上, 凝固过程主要受温度梯度方向的驱使, 取向与温度梯度方向夹角越小的晶粒占优生长. 在纵截面上, 晶粒的生长表现出弯曲生长以及“上三角”的晶粒特征, 温度梯度方向的渐变导致了晶粒弯曲, 相邻晶粒的竞争行为决定了晶粒形貌. 本文阐明了金属激光增材制造晶粒演变的机理, 有助于厘清增材制造热物理、化学、冶金过程, 为凝固组织的预测和调控提供理论指导. 此外, 该多尺度数学模型也适用于其他金属材料的激光增材制造过程.      

Intergranular strain evolution near fatigue crack tips in polycrystalline metals

The deformation field near a steady fatigue crack includes a plastic zone in front of the crack tip and a plastic wake behind it, and the magnitude, distribution, and history of the residual strain along the crack path depend on the stress multiaxiality, material properties, and history of stress intensity factor and crack growth rate. An in situ, full-field, non-destructive measurement of lattice strain (which relies on the intergranular interactions of the inhomogeneous deformation fields in neighboring grains) by neutron diffraction techniques has been performed for the fatigue test of a Ni-based superalloy compact tension specimen. These microscopic grain level measurements provided unprecedented information on the fatigue growth mechanisms. A two-scale model is developed to predict the lattice strain evolution near fatigue crack tips in polycrystalline materials. An irreversible, hysteretic cohesive interface model is adopted to simulate a steady fatigue crack, which allows us to generate the stress/strain distribution and history near the fatigue crack tip. The continuum deformation history is used as inputs for the micromechanical analysis of lattice strain evolution using the slip-based crystal plasticity model, thus making a mechanistic connection between macro- and micro-strains. Predictions from perfect grain-boundary simulations exhibit the same lattice strain distributions as in neutron diffraction measurements, except for discrepancies near the crack tip within about one-tenth of the plastic zone size. By considering the intergranular damage, which leads to vanishing intergranular strains as damage proceeds, we find a significantly improved agreement between predicted and measured lattice strains inside the fatigue process zone. Consequently, the intergranular damage near fatigue crack tip is concluded to be responsible for fatigue crack growth.     

油气在持续热壁下热着火发生的数值模拟

为了对油气在持续热壁下热着火发生过程进行数值模拟,耦合化学动力学模型、流体动力学模型及辐射传热模型,建立了油气热着火的统一模型。基于实验工况,模拟了受限空间中油气在持续热壁条件下热着火发生过程,并分析了温度、压力流场的演变特征,以及不同位置处温度、压力、层流速度、湍流速度和组分质量分数的变化曲线。通过模拟,发现油气热着火过程存在3个阶段,分别为加热初始阶段、加热中间阶段和热着火发生阶段。不同阶段存在的主要原因是化学反应和流动的主导作用不同。     

A multivariant micromechanical model for SMAs Part 2. Polycrystal model

An averaging scheme is developed to simulate the behavior of a polycrystalline shape memory alloy (SMA) specimen using the Multivariant Micromechanics approach. An untextured polycrystalline specimen is assumed to be formed by a number of randomly oriented single crystal grains. The previously developed Multivariant technique is used to model the response of each single crystal grain subjected to its stress field seen in the polycrystalline sample. Using spherical grains, the Eshelby–Kröner approach is used to formulate the interaction between grains and to determine the stress state in each individual grain. This model successfully captures the basic features of SMA polycrystalline response to loading and temperature. In addition, comparison is made to recent experimental data with fully triaxial load states. Reasonable qualitative agreement is obtained and some issues related to crystallography of the material model are addressed.     

A void nucleation and growth based damage framework to model failure initiation ahead of a sharp notch in irradiated bcc materials

A continuum damage framework is developed and coupled with an existing crystal plasticity framework, to model failure initiation in irradiated bcc polycrystalline materials at intermediate temperatures. Constitutive equations for vacancy generation due to inelastic deformation, void nucleation due to vacancy condensation, and diffusion-assisted void growth are developed. The framework is used to simulate failure initiation at dislocation channel interfaces and grain boundaries ahead of a sharp notch. Evolution of the microstructure is considered in terms of the evolution of inelastic deformation, vacancy concentration, and void number density and radius. Evolution of the damage, i.e., volume fraction of the voids, is studied as a function of applied deformation. Effects of strain rate and temperature on failure initiation are also studied. The framework is used to compute the fracture toughness of irradiated specimens for various loading histories and notch geometries. Crack growth resistance of the irradiated specimens are computed and compared to that of virgin specimens. Results are compared to available experimental data.     

FUNDAMENTAL SOLUTION BASED GRADED ELEMENT MODEL FOR STEADY-STATE HEAT TRANSFER IN FGM

A novel hybrid graded element model is developed in this paper for investigating thermal behavior of functionally graded materials (FGMs). The model can handle a spatially varying material property field of FGMs. In the proposed approach, a new variational functional is first constructed for generating corresponding finite element model. Then, a graded element is formulated based on two sets of independent temperature fields. One is known as intra-element temperature field defined within the element domain; the other is the so-called frame field defined on the element boundary only. The intra-element temperature field is constructed using the linear combination of fundamental solutions, while the independent frame field is separately used as the boundary interpolation functions of the element to ensure the field continuity over the interelement boundary. Due to the properties of fundamental solutions, the domain integrals appearing in the variational functional can be converted into boundary integrals which can significantly simplify the calculation of generalized element stiffness matrix. The proposed model can simulate the graded material properties naturally due to the use of the graded element in the finite element (FE) model. Moreover, it inherits all the advantages of the hybrid Trefftz finite element method (HT-FEM) over the conventional FEM and boundary element method (BEM). Finally, several examples are presented to assess the performance of the proposed method, and the obtained numerical results show a good numerical accuracy.     

Effect of thermal diffusion and electrostatic force on evolution of wind-blown sand flow

A theoretical model is suggested to mathematically describe the effect of thermal diffusion from a sand-bed on evolution of a wind-blown sand flow.An upward wind field is engendered by the thermal diffusion and the coupling interaction among the horizontal and upward wind flow,saltating grains,and a kind of electrostatic force exerted on the grains are considered in this theoretical model.The numerical results show that the effect of the thermal diffusion on the evolution process of wind-blown grain flow is quite obvious and very similar to the effect of the electrostatic force on the evolution.Not only the time for the entire system to reach a steady state(called the duration time),the transport rate of grains,the mass-flux profiles and the trajectory of saltating grains are affected by the thermal diffusion and the electrostatic force exerted on saltating grains, but also the wind profiles and the temperature profiles at the steady state are affected by the wind-blown sand flow.     

复杂应力状态下木材力学性能的数值模拟

针对木材复杂的各向异性材料特点,建立了能反映木材正交各向异性弹性、抗拉和抗压强度不等、抗拉或抗剪时发生脆性破坏而受压时发生塑性变形等特性的本构模型。将木材弹性应力—应变关系简化为正交各向异性;选用Yamada-Sun强度准则来判断木材抗压时是否屈服,抗拉或抗剪时是否发生应变软化;通过引入损伤因子和弹性应变能,建立了木材...     

Finite element modeling of tube hydroforming of polycrystalline aluminum alloy extrusions

Finite element modeling of tube hydroforming requires information about the anisotropy of the extruded aluminum tube. Unlike sheet metals, the complex geometry of extruded tubes makes it difficult, except in extrusion direction, to directly measure material properties. Therefore, polycrystalline models provide a good alternative for calculating the anisotropy of the tube in all directions and under various loading conditions. Using a rate-independent single crystal yield surface and rigid plasticity, a Taylor-type polycrystalline model was developed and implemented into ABAQUS/Explicit finite element (FE) code using VUMAT. The constitutive model was then used to calculate the crystallographic texture evolution during the hydroforming of an extruded aluminum tube. Initial crystallographic texture measured using orientation imaging microscopy (OIM) and uniaxial tensile test data obtained along the extrusion direction were input to this FEA model. In order to efficiently and practically simulate the tube hydroforming process using the polycrystalline model, sensitivity to the number of grain orientation, total simulation time, and number of finite elements were studied. Predicted results agreed very well with experimentally measured strain obtained from tube hydroforming process.     

Dissipative heating of elastomers: a new modelling approach based on finite and coupled thermomechanics

Especially in the automotive industries, elastomers take an important role. They are used in different types of bearings, where they inhibit vibration propagation and thereby significantly enhance driving performance and comfort. That is why several models have already been developed to simulate the material’s mechanical response to stresses and strains. In many cases, these models are developed under isothermal conditions. Others include the temperature-dependent mechanical behaviour to represent lower stiffness’s for higher temperatures. In this contribution it is shown by some exemplary experiments that viscoelastic material heats up under dynamic deformations. Hence, the material’s properties change due to the influence of the temperature without changing the surrounding conditions. With some of these experiments, it is shown that a fully coupled material model is necessary to predict the behaviour of bearings under dynamic loads. The focus of this contribution lies on the modelling of the thermoviscoelastic behaviour of elastomers. In a first step, a twofold multiplicative split of the deformation gradient is performed to be able to describe both mechanical and thermal deformations. This concept introduces different configurations. The stress tensors existing on these configurations are used to formulate the stress power in the first law of thermodynamics which allows to simulate the material’s self-heating. To formulate the temperature dependency of the mechanical behaviour, the non-equilibrium part of the Helmholtz free energy function is formulated as a function of the temperature and the deformation history. With the introduced model, some FE calculations are carried out to show the model’s capability to represent the thermoviscoelastic behaviour including the coupling in both directions.     

New approach based on continuum damage mechanics with simple parameter identification to fretting fatigue life prediction

A new continuum damage mechanics model for fretting fatigue life prediction is established. In this model, the damage evolution rate is described by two kinds of quantities. One is associated with the cyclic stress characteristics obtained by the finite element(FE) analysis, and the other is associated with the material fatigue property identified from the fatigue test data of standard specimens. The wear is modeled by the energy wear law to simulate the contact geometry evolution. A two-dimensional(2D) plane strain FE implementation of the damage mechanics model and the energy wear model is presented in the platform of ABAQUS to simulate the evolutions of the fatigue damage and the wear scar. The effect of the specimen thickness is also investigated. The predicted results of the crack initiation site and the fretting fatigue life agree well with available experimental data. Comparisons are made with the critical plane SmithWatson-Topper(SWT) method.     

Peridynamic modeling of pitting corrosion damage

In this paper we introduce a peridynamic model for the evolution of damage from pitting corrosion capable of capturing subsurface damage. We model the anodic reaction in corrosion processes (in which electroplating is negligible) as an effective peridynamic diffusion process in the electrolyte/solid system coupled with a phase-change mechanism that allows for autonomous evolution of the moving interface. In order to simulate creation of subsurface damage, we introduce a corrosion damage model based on a stochastic relationship that connects the concentration in the metal to the damage of peridynamic mechanical-bonds that are superposed onto diffusion-bonds. We study convergence of this formulation for diffusion-dominated stage. The model leads to formation of a subsurface damage layer, seen in experiments. We validate results against experiments on pit growth rate and polarization data for pitting corrosion. We extend the 1D model to the 2D and 3D, and introduce a new damage-dependent corrosion model to account for broken mechanical bonds that enhance the corrosion rate. This coupled model can predict the pit shape and damage profile in materials with microstructural heterogeneities, such as defects, interfaces, inclusions, and grain boundaries.     

Molten droplet solidification and substrate remelting in microcasting Part I: numerical modeling and experimental verification

This paper presents a numerical model of a molten metal droplet impinging, solidifying and bonding to a solid substrate. The physical and numerical model includes dissimilar materials, multi-dimensional axisymmetric heat transfer, tracking of solid/liquid interfaces during remelting and solidification, and coupled treatment of the continuous droplet/substrate region. The numerical model solves for the evolution of the temperature distribution in the droplet and substrate, predicts the position of the remelting and solidification fronts, and accounts for convective motion. The effect of the convection induced by the droplet spreading is modeled through a time-dependent effective thermal conductivity. High-speed filming of the molten droplet impinging and spreading on the substrate is performed to obtain the required parameters to determine this time dependent effective conductivity. The accuracy of the model is investigated with experimental techniques. This research is directly related to the development of microcasting Shape Deposition Manufacturing (SDM) which is a process for automatically fabricating complex multi-material objects by sequentially depositing material layers. Microcasting is a molten metal droplet deposition process in SDM, which is able to create fully dense metal layers with controlled microstructure. Important issues in the production of high quality objects manufactured with microcasting SDM are: attainment of interlayer metallurgical bonding through substrate remelting, control of both substrate and droplet cooling rates, and minimization of residual thermal stresses. To validate experimentally the numerical modeling approach, predicted cooling rates are compared with thermocouple measurements and substrate remelting depths are verified through optical metallographic techniques. Received on 10 June 1998     

Effect of “Stefan” currents of a solidifying melt on the process of thermal convection

The calculated results, represented by graphs, show that in the initial period of solidification the motion of a melt is fully determined by the shrinkage at the front of crystallization. The effect develops more strongly at lower Grashof numbers and higher Stefan numbers. As the rate of solidification and the temperature gradient decrease the process of natural thermal convection develops in the liquid phase. The calculated results are compared with experiment.     

A thermomechanical model for the analysis of light alloy solidification in a composite mould

A coupled thermomechanical model to simulate light alloy solidification problems in permanent composite moulds is presented. This model is based on a general isotropic thermoelasto-plasticity theory and considers the different thermomechanical behaviours of each component of the mould as well as those of the solidifying material during its evolution from liquid to solid. To this end, plastic evolution equations, a phase-change variable and a specific free energy function are proposed in order to derive temperature-dependent material constitutive laws.The corresponding finite element formulation and the staggered scheme used to solve the coupled non-linear system of equations are also presented. Finally, the temperature and displacement predictions of the model are validated with laboratory measurements obtained during an experimental trial.     

Analysis on high-temperature oxidation and growth stress of iron-based alloy using phase field method

High-temperature oxidation is an important property to evaluate thermal protection materials. However, since oxidation is a complex process involving microstructure evolution, its quantitative analysis has always been a challenge. In this work, a phase field method (PFM) based on the thermodynamics theory is developed to simulate the oxidation behavior and oxidation induced growth stress. It involves microstructure evolution and solves the problem of quantitatively computational analysis for the oxidation behavior and growth stress. Employing this method, the diffusion process, oxidation performance, and stress evolution are predicted for Fe-Cr-Al-Y alloys. The numerical results agree well with the experimental data. The linear relationship between the maximum growth stress and the environment oxygen concentration is found. PFM provides a powerful tool to investigate high-temperature oxidation in complex environments.     

有限变形下单晶变温本构模型

本文构造了单晶热弹粘塑性的本构模型,模拟材料在不同温度下的力学行为。该模型以晶体热运动学作为分析变形的基础,即考虑温度变化情况下总体变形梯度的乘式分解,建立温度影响下的以弹性变形梯度为基本变量的控制方程来描述单晶材料的变形,算法采用隐式积分方法来求解控制方程以保证计算的稳定性。模型能反映单晶材料变形过程中温度对应力-应变响应的影响。     

Micromechanical modelling of cyclic plasticity incorporating damage

In this paper a numerical investigation on the possibility to simulate and predict cyclic plastic response incorporating damage has been performed. To this purpose, unit cell and continuum approaches based on porous metal plasticity and continuum damage mechanics (CDM) have been considered. In particular, the porous metal plasticity model of Leblond, Perrin and Devaux (LPD model) and the CDM model developed by Pirondi and Bonora were used. Finite element (FE) simulations were performed for each approach with different degrees of triaxiality and the results are analyzed and compared.     

Analysis on high-temperature oxidation and growth stress of iron-based alloy using phase field method

High-temperature oxidation is an important property to evaluate thermal protection materials. However, since oxidation is a complex process involving microstructure evolution, its quantitative analysis has always been a challenge. In this work, a phase field method (PFM) based on the thermodynamics theory is developed to simulate the oxidation behavior and oxidation induced growth stress. It involves microstructure evolution and solves the problem of quantitatively computational analysis for the oxidation behavior and growth stress. Employing this method, the diffusion process, oxidation performance, and stress evolution are predicted for Fe-Cr-Al-Y alloys. The numerical results agree well with the experimental data. The linear relationship between the maximum growth stress and the environment oxygen concentration is found. PFM provides a powerful tool to investigate high-temperature oxidation in complex environments.