In Situ Observation of Adiabatic Shear Band Formation in Aluminum Alloys

We used high-speed X-ray phase contrast imaging and infrared thermal imaging techniques to study the formation processes of adiabatic shear bands in aluminum 7075-T6 and 6061-T6 alloys. A modified compression Kolsky bar setup was used to apply the dynamic loading. A flat hat-shaped specimen design was adopted for generating the shear bands at the designated locations. Experimental results show that 7075-T6 exhibits less ductility and a narrower shear band than 6061-T6. Maximum temperatures of 720 K and 770 K were locally determined within the shear band zones for 7075-T6 and 6061-T6 respectively. This local high temperature zone and the resulting thermal instability were found to relate to the shear band formation in these aluminum alloys.

     

Free–free opacity in warm dense aluminum

We present calculations of the free–free opacity of warm, solid-density aluminum at photon energies between the plasma frequency at 15 eV and the L-edge at 73 eV, using both density functional theory combined with molecular dynamics and a semi-analytical model in the RPA framework which includes exciton contributions. As both the ion and electron temperature is increased from room temperature to 10 eV, we see a marked increase in the opacity. The effect is less pronounced if only the electron temperature is allowed to increase, while the lattice remains at room temperature. The physical significance of these increases is discussed in terms of intense light-matter interactions on both femtosecond and picosecond time scales.     

超高速撞击下碎片云的OTM分析

空间碎片超高速撞击是典型的高温、高压、高应变率的极限力学问题，涉及材料复杂的动态响应，对传统的数值方法提出了巨大挑战。最优运输无网格（OTM）方法通过有机结合最优运输时间积分理论、局部最大熵无网格近似、物质点抽样、基于物理的裂纹扩展算法以及大规模并行计算策略，克服了传统数值方法瓶颈，在理论上保证了不同形式能量耗散的自主耦合分配，为超高速撞击仿真预测提供了高效的解决方案。采用基于OTM方法自主研发的极限力学仿真软件ESCAAS，对不同质量（3、10 g）的铜飞片以不同撞击角度（5.4°、11.7°）和不同撞击速度（5.55、5.12 km/s）撞击铝合金靶板的过程进行数值模拟，获得碎片云的形貌、靶板穿孔孔径等结果，与实验测量数据吻合良好，显示出OTM方法及ESCAAS软件可以作为超高速撞击的有力数值分析手段。     

Damage Accumulation in Aluminum Alloys under Plastic Deformation and Creep

The accumulation of local and bulk damage in D16 AT and 1201 T1 aluminum alloys used in aircraft engineering is studied. The local damage level is calculated from data of thermoactivation analysis of the residual life of D16 AT alloy specimens after preliminary plastic deformation. The bulk damage level is determined from the elastic-modulus defect by measuring the natural frequency of 1201 T1 alloy specimens. Life tests of the specimens were performed at constant tensile loads and elevated temperatures. The dependence of the local damage on preliminary plastic strain at room temperature is obtained. The residual life of the specimens is calculated with allowance for the damage to the material in the initial stage of failure and compared with experimental results. Data are given on the kinetics of bulk-damage accumulation in various test regimes. __________ Translated from Prikladnaya Mekhanika i Tekhnicheskaya Fizika, Vol. 47, No. 1, pp. 172–182, January–February, 2006.     

Electron scattering in hot/warm plasmas

Electrical and thermal conductivities are presented for aluminum, iron and copper plasmas at various temperatures, and for gold between 15,000 and 30,000 K. The calculations are based on the continuum wave functions computed in the potential of the temperature and density dependent self-consistent ‘average atom’ (AA) model of the plasma. The cross-sections are calculated by using the phase shifts of the continuum electron wave functions and also in the Born approximation. We show the combined effect of the thermal and radiative transport on the effective Rosseland mean opacities at temperatures from 1 to 1000 eV. Comparisons with low temperature experimental data are also presented.     

3D numerical simulations of ductile targets subjected to oblique impact by sharp nosed projectiles

Three-dimensional numerical simulations have been performed to study the behaviour of ductile targets subjected to normal and oblique impact by sharp nosed cylindrical projectiles. Twelve-mm-thick Weldox 460 E steel targets were impacted by 20 mm diameter projectiles with conical nose and 1-mm-thick 1100-H12 aluminum targets were impacted by 19 mm diameter ogive nosed projectiles. In both the cases, the targets were impacted at 0°, 15°, 30°, 45° and 60° obliquity or until the ricochet of the projectile occurred. The ballistic limit of 12 mm steel targets was found to be almost same up to 30° obliquity and thereafter it increased sharply. However, in the case of 1 mm aluminum targets a consistent increase in the ballistic limit was observed with increase in obliquity. The critical angle of projectile ricochet was found to increase with increase in impact velocity. Both the targets failed through ductile hole enlargement. Petal formation occurred in the aluminum targets and four petals were generally formed in each plate, however, the size of the upper two petals decreased and that of the lower two petals increased with increase in target obliquity. In the case of the steel targets the perforation occurred through the formation of a hole enclosed by a bulge. Both the bulge and the hole were circular in normal impact and elliptical in oblique impact. Petal formation in steel targets was observed at 60° obliquity. The ABAQUS/explicit finite element code was used to carry out numerical simulations.     

Measuring magnetic fields in single aluminum wire plasmas with time-resolved optical spectroscopy

Using time-resolved emission spectroscopy at visible wavelengths, we explored the conditions of plasmas generated by current-driven explosions of single aluminum wires. The experiments were carried out with 15 μm aluminum wires driven by the Low Current Pulser 3 (LCP3) at Cornell University.The plasma conditions were studied as a function of time and radial position, including electron temperature, electron density, ionization state, and magnetic field. To determine the magnetic field, we are working toward employing a new diagnostic method which makes use of Zeeman-effect-produced differences in the line shapes of two fine structure components of a multiplet that are equally broadened by Stark effect and by Doppler broadening. Preliminary results and data collected by a spectroscopy system with 3.2 Å resolution are presented.     

Flow stress behavior of porous FVS0812 aluminum alloy during hot-compression

The hot deformation behavior of porous FVS0812 aluminum alloy prepared by spray deposition was studied by means of compression tests on a Gleeble 1500 machine. The samples were hot compressed at temperatures ranging from 573 K to 773 K under various true strain rates of 10⁻⁴–10⁰ s⁻¹. The deformation behaviors are characterized by a significant strain hardening during hot-compression due to the progressive compaction of the pores with increasing compressive strain. A revised formula describing the relationships of the flow stress, strain rate and temperature of the porous alloy at elevated temperatures is proposed by compensation of strain. The theoretical predictions are compared with experimental results, which show good agreement.     

Mechanical behavior of Gamma-Met PX under uniaxial loading at elevated temperatures and high strain rates

Gamma titanium aluminides have received considerable attention over the last decade. These alloys are known to have low density, good high temperature strength retention and good oxidation and corrosion resistance. However, poor ductility and low fracture toughness have been the key limiting factors in the full utilization of these alloys. More recently, a new generation of gamma titanium aluminide alloys, commonly referred to as Gamma-Met PX, has been developed by GKSS, Germany. These alloys have been observed to have superior strength and better oxidation resistance at elevated temperatures when compared with conventional gamma titanium aluminides.The present paper discusses results of a study to understand the uniaxial mechanical behavior in both compression and tension of Gamma-Met PX at elevated temperatures and high strain rates. The compression and tensile tests are conducted using a modified Split-Hopkinson Bar apparatus at test temperatures ranging from room temperature to 900 °C and strain rates of up to 3500 s⁻¹. Under uniaxial compression, in the temperature range from room to 600 °C, the flow stress is observed to be nearly independent of test temperature. However, at temperatures higher than 600 °C thermal softening is observed at all strain rates with the rate of thermal softening increasing dramatically between 800 and 900 °C. The room temperature tensile tests show negligible strain-rate dependence on both yield stress and flow stress. With an increase in test temperature from room to 900 °C, the material shows a drop in both yield and flow stress at all levels of plastic strain. However, the measured flow stress is still higher when compared to nickel based super-alloys and other gamma titanium aluminides under similar test conditions. Also, no anomaly in yield stress is observed up to 900 °C.     

Measurements of opacity and temperature of warm dense matter heated by focused soft X-ray laser irradiation

The transmission of plasma-based soft X-ray lasers through thin targets can be used to measure the target opacity. Measurements of warm dense matter transmission obtained using a focused 59 eV photon energy laser irradiation on thin targets of polyimide (C₂₂H₁₀N₂O₅) and aluminum are shown to produce simultaneous heating and probing enabling opacity and temperature measurements of warm dense matter. It is shown that the opacity of the warm dense matter considered in the experiments follows closely tabulated cold ‘room temperature’ opacities at temperatures below ～10 eV. Transmission measurements of thin iron targets which are highly opaque to the X-ray laser radiation are also presented.     

7A04铝合金的本构关系和失效模型

使用万能材料试验机、扭转试验机和Taylor撞击实验研究了高强铝合金7A04在常温至250 ℃的 准静态、动态本构关系和失效模型。基于实验结果,修改了Johnson-Cook强度模型中的应变强化项以及 Johnson-Cook失效模型中的温度软化项,并结合数值模拟标定了模型参数。实验结果表明,7A04铝合金的 应变和应变率强化效应不显著,失效应变随温度的增加、应力三轴度的减小和应变率的减小而增加。     

Forming of AA5182-O and AA5754-O at elevated temperatures using coupled thermo-mechanical finite element models

A temperature-dependent anisotropic material model was developed for two aluminum alloys AA5182-O and AA5754-O and their anisotropy parameters were established. A coupled thermo-mechanical finite element analysis of the forming process was then performed for the temperature range 25–260 °C (77–500 °F) at different strain rates. In the developed model, the anisotropy coefficients for Barlat’s YLD2000-2d anisotropic yield function [Barlat, F., Brem, J.C., Yoon, J.W., Chung, K., Dick, R.E., Lege, D.J., Pourboghrat, F., Choi, S.H., Chu, E., 2003. Plane stress yield function for aluminum alloy sheets – Part 1: Theory. Int. J. Plasticity 19, 1297–1319] in the plane-stress condition and the parameters for the isotropic strain hardening were established as a function of temperature. The temperature-dependent anisotropic yield function was then implemented into the commercial FEM code LS-DYNA as a user material subroutine (UMAT) using the cutting-plane algorithm for the integration of a general class of elastoplastic constitutive models [Abedrabbo, N., Pourboghrat, F., Carsley, J., 2006b. Forming of aluminum alloys at elevated temperatures – Part 2: Numerical modeling and experimental verification. Int. J. Plasticity 22 (2), 342–737]. The temperature-dependent material model was used to simulate the coupled thermo-mechanical finite element analysis of the stamping of an aluminum sheet using a hemispherical punch under the pure stretch boundary condition (no material draw-in was allowed). Simulation results were compared with experimental data at several elevated temperatures to evaluate the accuracy of the UMAT’s ability to predict both forming behavior and failure locations. Two failure criteria were used in the analysis; the M–K strain based forming limit diagrams (ε-FLD), and the stress based forming limit diagrams (σ-FLD). Both models were developed using Barlat’s YLD2000-2d anisotropic model for the two materials at several elevated temperatures. Also, as a design tool, the Genetic Algorithm optimization program HEEDS was linked with the developed thermo-mechanical models and used to numerically predict the “optimum” set of temperatures that would generate the maximum formability for the two materials in the pure stretch experiments. It was found that a higher temperature is not needed to form the part, but rather the punch should be maintained at the lowest temperature possible for maximum formability.     

Examination of multispectral radiation thermometry using linear and log-linear emissivity models for aluminum alloys

Multispectral radiation thermometry (MRT) using two commonly used emissivity models, linear emissivity models (LEM) and log-linear emissivity models (LLE), was used to predict the aluminum surface temperature. Experiments were conducted to measure the spectral intensity values for five different aluminum alloys at three different temperatures. Overall, three emissivity models give good results most frequently and provide the best compensation for different alloys, the number of wavelengths, temperatures, and heating time.     

Measurements on the magnetic susceptibilities of Ag-Mn and Cu-Mn alloys

Summary Measurements have been carried out on alloys of Ag-Mn and Cu-Mn with different concentrations of manganese between room temperature and liquid hydrogen temperatures. A paramagnetic behaviour has been found. We examined especially the dependence of the susceptibilities on the field strength; no field dependence could be detected except in some of the Ag-Mn alloys, but this effect originated from small ferromagnetic impurities which were determined by means of the method of Honda. The concentration of the maganese has been determined magnetically and compared with determinations based on the electrical resistance.We take the opportunity to express our warm thanks to the Union Minière du Haut Katanga for financial help during these measurements. We also thank Dr. G. J. van den Berg, conservator at the Kamerlingh Onnes Laboratory. Leiden, who put the samples at our disposal.     

Fluctuations and the ionization potential in dense plasmas

A semi-analytic model is developed to estimate continuum lowering in dense plasmas including fluctuations. The model is applied to aluminum and compared with recent experiments at the Linac Coherent Light Source [O. Ciricosta et al., Phys. Rev. Lett. 109 (2012) 065002] that reported the ionization potential depression of K-shell electrons in solid density aluminum at temperatures up to 180 eV. The analysis suggests fluctuations, which are neglected in most continuum lowering models but are essential to describe energy absorption by a system, are sufficiently large to impact the interpretation of the experimental results.     

A High-frequency High-temperature Optical Strain/Displacement Gage

This paper describes an optical method for measuring strain or crack-opening displacement at high frequencies (20 kHz) and high temperatures (590°C) on a near-real-time basis. Two small reflective markers are placed on a smooth specimen or across a crack. When illuminated with a laser, interference fringes are generated; their motion can be monitored with photomultiplier tubes. The data acquisition system acquires 200 points per 50 microsecond cycle. These are processed, displayed, and stored at a rate of 25 Hz. Applications are in the general area of very high cycle (10⁹ cycles or more) fatigue. Demonstration tests at 20 kHz at room temperature with a strain range of 0.45 percent and at 590°C with a range of 0.2 percent are presented along with room temperature displacements up to 0.7 μm across the center of a 1.4 mm long crack.     

Acoustic emission and the Portevin-Le Chatelier effect

Many metals and alloys which exhibit repeated discontinuous yielding (Portevin-Le Chatelier effect) also emit rather interesting acoustic energy during work hardening. Both phenomena are dramatic in dead-weight extensions of annealed specimens of brass or aluminum. The acoustic emission from such specimens was monitored and correlated with the features of the Portevin-Le Chatelier effect. It is shown that, when the discontinuous yielding subsides in aluminum, so does the acoustic emission; in fact, smooth continuous flow can occur in these materials with no detectable acoustic emission. Data are presented which are consistent with the hypothesis that, at room temperature, elastic energy released during a yield increment is proportional to the elastic energy stored since the last yield increment. This is not observed at elevated temperatures. It is concluded that additional studies of the acoustic-emission phenomena associated with plastic deformation can aid in achieving a better knowledge of the strain-hardening process for crystalline solids.     

Effect of projectile nose shape on the ballistic resistance of ductile targets

Three-dimensional numerical simulations were carried out to study the ballistic resistance of ductile targets subjected to normal impact by the projectiles. 12 mm thick Weldox 460 E steel targets were impacted by 20 mm diameter conical nosed projectiles and 1 mm thick 1100-H12 aluminum targets were impacted by 19 mm diameter ogive nosed projectiles. The internal nose angle of conical projectile was varied (33.4°–180°) and found to have significant effect on the ballistic limit of 12 mm thick Weldox 460 E steel target. Similarly, the caliber radius head (CRH) of ogive nosed projectile was varied (0–2.5) and found to have significant effect on the ballistic limit of 1 mm thick 1100-H12 aluminum target. The ballistic limit of 12 mm thick Weldox 460 E steel target increased almost linearly with the decrease in the projectile nose angle. While the ballistic limit of 1 mm thick 1100-H12 aluminum target increased as the CRH increased from 0 to 0.5 and with further increase in CRH to 1.0, 1.5, 2.0 and 2.5 its values were found to drop quite significantly. ABAQUS/Explicit finite element code was used to carry out the numerical simulations.     

A fast response thermocouple for internal combustion engine surface temperature measurements

A fast response thermocouple was developed for measuring surface temperatures of aluminum components in ICE combustion chambers. The key features of the design are the use of the aluminum substrate as one of the thermocouple metals and the use of a thick copper layer as the hot junction at the surface. The copper equalizes the hot junction temperature with the surrounding aluminum to correct for the differences in thermal properties between the two materials. FEA determined the optimum thickness of the copper layer to be between 100 and 125 μm. Under typical SI engine heat flux conditions, the thermocouple should be able to measure average surface temperatures within 0.19 °C and the magnitude of temperature swings within 6% of true values.Following the FEA, the optimized thermocouple was tested in a SI engine. Experimental results displayed the same trends as the FEA at measuring average temperatures and temperature swings, suggesting the thermocouple was performing as predicted.     

Preparation and characterization of core-shell Al@PFHP with improving the combustion and ignition properties of aluminum powder

The dense alumina shell on the surface of aluminum powder will hinder the combustion of aluminum powder and increase its ignition temperature. In this study, the aluminum oxide shell layer on the surface of aluminum powder was removed with hydrofluoric acid by one-pot method, and 3-Perfluorohexyl-1, 2-epoxypropane (PFHP) (F₃C(CF₂)₅CH₂C₂H₃O) was coated to form a uniform and controllable core-shell Al@PFHP. The core-shell Al@PFHP showed better thermal reaction and ignition performance. The exothermic enthalpy of Al@0.15 PFHP was increased by about 1.9 times, with lower ignition temperature (reduced by about 140 °C) and longer burning duration (increased by about 1.5 times) after coating with PFHP, compared with raw aluminum powder. In addition, the formation of PFHP coating shell can effectively improve the hydrophobicity and corrosion resistance of aluminum powder.