A new unified constitutive model with short- and long-range back stress for lead-free solders of Sn–3Ag–0.5Cu and Sn–0.7Cu

A series of tensile tests of Sn–3Ag–0.5Cu and Sn–0.7Cu lead-free solders were investigated at various strain rates from 1 × 10⁻⁴ s⁻¹ to 1 × 10⁻² s⁻¹ and over a wide temperature range from 25 ^oC to 150 ^oC. Two-step strain rate jump tests, three-step short term creep tests with stress jump, and uniaxial ratcheting tests were also conducted. Based on the test data, a new constitutive model was proposed with a simple formulation and only eight material constants which can be easily obtained. The model employs two carefully defined back stress components to simulate the loading/unloading asymmetry phenomenon in uniaxial ratcheting tests. Different evolution rules of short-range back stress were given for loading and unloading stage, which provides the model ability to simulate the asymmetry in hysteresis loops. The proposed model presents good simulation of uniaxial tensile tests, strain rate jump tests, short term creep tests with stress jump, and uniaxial ratcheting tests.     

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.     

Experimental investigation and modeling of the tension behavior of polycarbonate with temperature effects from low to high strain rates

The effects of strain rate and temperature on the tension stress–strain responses of polycarbonate are experimentally investigated over a wide range of strain rates (0.001–1700 s⁻¹) and temperatures (0–120 °C). A modified split Hopkinson tension bar is used for high-rate uniaxial tension tests. Experimental results indicate that the stress–strain responses of polycarbonate at high strain rates exhibit the nonlinear characteristics including the obvious yielding and strain softening. The tension behavior is strongly dependent on the strain rate and temperature. The values of yield stress and strain at yield present a dramatic increase at higher strain rates and decrease with the increase in temperature. Moreover, there exists a significant rate-sensitivity transition in the polycarbonate tension yield behavior. Based on the experimental investigation, a physically based three-dimensional elastoplastic constitutive model for the finite deformation of glassy polymers is used to characterize the rate-temperature dependent yield and post-yield behavior of polycarbonate when subjected to tension loading. The model results are shown close to the experimental data within the investigated strain-rate and temperature ranges.     

Rate dependent critical strain energy density factor of Huanglong limestone

Critical strain energy density of rock can be defined as a fundamental parameter in rock fracture mechanics, an intrinsic material property related to resistance to crack initiation and propagation. By means of the three-point bending experiments, the critical strain energy density factor of Huanglong limestone was measured over a wide range of loading rates from 8.97 × 10⁻⁴ MPam^1/2 s⁻¹ to 1.545 MPam^1/2 s⁻¹. According to the approximate relationship between static and dynamic critical strain energy density factor of Huanglong limestone, relationship between the growth velocity of crack and magnitude of load is obtained. The main conclusions are summarized as follows: (1) when the loading rate is higher than 0.0279 MPam^1/2 s⁻¹, the critical strain energy density factor of rock increased markedly with increasing loading rate. However, when loading rate is lower than 0.0279 MPam^1/2 s⁻¹, the critical strain energy density factor slightly increased with an increase in loading rate. It is found from experimental results that the critical strain energy density factor is linear proportional to the exponential expression of loading rate, (2) for Huanglong limestone, when the growth velocity of crack is lower than 100 m/s, value of the maximum load was nearly a constant. However, when the growth velocity of crack is higher than 1000 m/s, value of the maximum load dramatically increases with increasing the crack growth velocity, and (3) the critical SED of Huanglong limestone is higher as the loading rate is higher.     

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.     

Thermo-mechanical response of Al 6061 with and without equal channel angular pressing (ECAP)

The thermo-mechanical responses of Al 6061 before and after equal channel angular pressing (ECAP) at different strain rates and temperatures were measured. Al 6061 was solution heat treated before ECAP pressing at room temperature and subjected to up to three passes. After pressing, the billets were aged at 100 °C for 2 days. An as-received Al 6061-T651 was studied similarly to investigate the differences between processed and non-processed specimens. The responses of ECAP material were determined at −30, 22, 125 and 250 °C, and at strain rates from 10⁻⁵ to 2530 s⁻¹; the 6061-T651 specimens were subjected to uniaxial compressive loading at −31, 22, 85, 150, 230 and 315 °C, and strain rates ranging from 10⁻⁵ to 2200 s⁻¹. It was found that, the ECAP process increases the strength versus the T651 condition. Additionally, the Al 6061 ECAP is not sensitive to strain rate at room and lower temperatures, but the sensitivity increases as the number of passes and/or temperature are increased and this is the same for the non-processed material. Increasing the number of passes increases the flow stress at room and lower temperatures, has almost no effect at 125 °C and decreases at 250 °C. For both materials, the dynamic flow stress is higher than the stress at quasi-static strain rates even when the quasi-static strain rate regime is insensitive to strain rate. The Al 6061 has strong texture after one pass but steadily increases as the number of passes are increased. This is the first study that reports on the thermo-mechanical responses of ECAP and non-ECAP Al 6061 at such a wide range of strain rates, including dynamic, and temperatures.     

Effect of oxygen content and microstructure on the thermo-mechanical response of three Ti–6Al–4V alloys: Experiments and modeling over a wide range of strain-rates and temperatures

Results from a series of experiments on three different titanium alloys, under quasi-static and dynamic loading conditions are presented. The Ti–6Al–4V titanium alloys include the ELI version and two with higher oxygen contents. The strain-rates are varied from 10⁻⁶ to 3378 s⁻¹ while observations are made at temperatures from 233 to 755 K. The alloys initial and deformed photomicrographs and various deformation mechanisms responsible for the induced plastic deformation, are presented and discussed. Differences in the responses of these alloys are observed in terms of thermal softening, work hardening, and strain-rate and temperature sensitivities. The Khan–Huang–Liang (KHL) model is used to effectively simulate the observed responses obtained from these experiments. The model, with the constants determined from these experiments, is then used to predict strain-rate jump experimental results, and also high temperature dynamic experiments for one of the alloys; the predictions are found to be very close to the observations.     

Multiaxial and non-proportional loading responses,anisotropy and modeling of Ti–6Al–4V titanium alloy over wide ranges of strain rates and temperatures

Results from a series of multiaxial loading experiments on the Ti–6Al–4V titanium alloy are presented. Different loading conditions are applied in order to get the comprehensive response of the alloy. The strain rates are varied from the quasi-static to dynamic regimes and the corresponding material responses are obtained. The specimen is deformed to large strains in order to study the material behavior under finite deformation at various strain rates. Torsional Kolsky bar is used to achieve shear strain rates up to 1000 s⁻¹. Experiments are performed under non-proportional loading conditions as well as dynamic torsion followed by dynamic compression at various temperatures. The non-proportional loading experiments comprise of an initial uniaxial loading to a certain level of strain followed by biaxial loading, using a channel-type die at various rates of loadings. All the non-proportional experiments are carried out at room temperature. Experiments are also performed to investigate the anisotropic behavior of the alloy. An orthotropic yield criterion [proposed by Cazacu, O., Plunkett, B., Barlat, F., 2005. Orthotropic yield criterion for hexagonal closed packed metals. International Journal of Plasticity 22, 1171–1194.] for anisotropic hexagonal closed packed materials with strength differential is used to generate the yield surface. Based on the definition of the effective stress of this yield criterion, the observed material response for the different loading conditions under large deformation is modeled using the Khan–Huang–Liang (KHL) equation assuming isotropic hardening. The model constants used in the present study, were pre-determined from the extensive uniaxial experiments presented in the earlier paper [Khan, A.S., Suh, Y.S., Kazmi R., 2004. Quasi-static and dynamic loading responses and constitutive modeling of titanium alloys. International Journal of Plasticity 20, 2233–2248]. The model predictions are found to be extremely close to the observed material response.     

A model for plasticity kinetics and its role in simulating the dynamic behavior of Fe at high strain rates

The recent diagnostic capability of the Omega laser to study solid-solid phase transitions at pressures greater than 10 GPa and at strain rates exceeding 10⁷ s⁻¹ has also provided valuable information on the dynamic elastic-plastic behavior of materials. We have found, for example, that plasticity kinetics modifies the effective loading and thermodynamic paths of the material. In this paper we derive a kinetics equation for the time-dependent plastic response of the material to dynamic loading, and describe the model’s implementation in a radiation-hydrodynamics computer code. This model for plasticity kinetics incorporates the Gilman model for dislocation multiplication and saturation. We discuss the application of this model to the simulation of experimental velocity interferometry data for experiments on Omega in which Fe was shock compressed to pressures beyond the α-to-ε phase transition pressure. The kinetics model is shown to fit the data reasonably well in this high strain rate regime and further allows quantification of the relative contributions of dislocation multiplication and drag. The sensitivity of the observed signatures to the kinetics model parameters is presented.     

Numerical simulations of necking during tensile deformation of aluminum single crystals

Finite element simulations are used to study strain localization during uniaxial tensile straining of a single crystal with properties representative of pure Al. The crystal is modeled using a constitutive equation incorporating self- and latent-hardening. The simulations are used to investigate the influence of the initial orientation of the loading axis relative to the crystal, as well as the hardening and strain rate sensitivity of the crystal on the strain to localization. We find that (i) the specimen fails by diffuse necking for strain rate exponents m < 100, and a sharp neck for m > 100. (ii) The strain to localization is a decreasing function of m for m < 100, and is relatively insensitive to m for m > 100. (iii) The strain to localization is a minimum when the tensile axis is close to (but not exactly parallel to) a high symmetry direction such as [1 0 0] or [1 1 1] and the variation of the strain to localization with orientation is highly sensitive to the strain rate exponent and latent-hardening behavior of the crystal. This behavior can be explained in terms of changes in the active slip systems as the initial orientation of the crystal is varied.     

Falling film flow along steep two-dimensional topography: The effect of inertia

Steady film flow along a vertical wall with isolated step changes is studied numerically for Reynolds numbers Re ∼ O(10⁻³–10²) and capillary numbers Ca ∼ O(10⁻²–10¹). The lengthscale of free surface capillary features upstream of a step-in or step-out decreases uniformly with Re and switches from a −1/3 to a −1/2 power-law dependence on Ca. The height of the capillary features first grows with Re, but eventually diminishes when inertia forces overpower capillary forces. Simultaneously, the key dynamics move from upstream to downstream of the step, and switch from capillary arrest to inertial re-directioning of the falling liquid. The latter mechanism involves a low-pressure region originating from the edge of the step. At a step-out, a new free surface feature appears with increasing Re, which is caused by liquid overshoot in the horizontal direction and is restrained initially by capillary and subsequently by inertial forces. Simple scaling arguments are shown to predict many of the above characteristics.     

Flow patterns of n-hexadecane–CO2 liquid–liquid two-phase flow in vertical pipes under high pressure

To promote a better understanding of liquid–liquid two-phase flow behavior, particularly under high pressure, flow patterns of n-hexadecane–CO₂ liquid–liquid two-phase upward flow in vertical stainless steel pipes were experimentally investigated. Observations were made in two 0.0015 m I.D. pipes of different lengths (0.068 m and 0.5 m) under high pressure varying from 10.3 to 29.6 MPa using a high pressure visualization system. The total flow rate was fixed at 2.0 × 10⁻⁶ m³/min, while the flow rate ratio (φ) varied from 0.05 to 19. Bubbly flow, plug flow, slug flow, annular flow, and near-one-phase flow regions were found in both pipes, while stratified flow was observed only in the 0.068 m pipe. Flow pattern maps were constructed in the flow rate ratio versus pressure graph, which demonstrates significant impacts of flow rate ratio, pipe length, and pressure on flow patterns. These impacts are discussed in detail. To the authors’ best knowledge, this work is the first attempt to observe complex liquid–liquid two-phase flow behavior with flow pattern transitions under high pressure, and contributes to a better understanding of liquid–liquid two-phase flow behavior.     

The role of dislocation walls for nanoindentation to shallow depths

Dislocation events are seen as excursions or pop-in events in the load–displacement curve of nanoindentation experiments. Two nanoindenters have been used to examine the difference between quasi-static and dynamic loading during indentation. Yield excursions were present in the load–displacement curves of both the statically and dynamically loaded single crystal nickel samples. Only one major excursion occurred in each quasi-static indent, nominally loaded at 100 μN/s while staircase yielding was observed under dynamic loading indentation with a 45 Hz oscillation of 2 nm superimposed on a 60 μN/s loading rate. Thermal activation analysis is used to explain the arrest and reinitiation of the yielding with activation volumes being modeled. For nanoindentation experiments differences between quasi-static and dynamic loading are described by the models presented. It is proposed that insight into the plastic deformation mechanisms associated with such plastic instabilities will provide one of the keys to length scale effects necessary to understanding nanostructures.     

Experimental study of inverted annular film boiling in a vertical tube cooled by R-134a

An experimental investigation of inverted annular film boiling heat transfer has been performed for vertical up-flow in a round tube. The experiments used R-134a coolant and covered a pressure range of 640–2390 kPa (water equivalent range: 4000–14,000 kPa) and a mass flux range of 500–4000 kg m⁻² s⁻¹ (water equivalent range: 700–5700 kg m⁻² s⁻¹). The inlet qualities of the tests ranged from −0.75 to −0.03. The hot-patch technique was used to obtain the subcooled film boiling measurements. It was found that the heat transfer vs. quality curve can be divided into four different regions, each characterized by a different mechanisms and trends. These regions are dependent on pressure, mass flux and local quality. A detailed examination of the parametric trends of the heat transfer coefficient with respect to mass flux, inlet quality, heat flux and pressure was performed; reasonably good agreement between observed trends and those reported in the literature were noted.     

Three phase liquid–liquid–gas flows in 5.6 mm and 7 mm inner diameter pipes

Three phase liquid–liquid–gas flow maps in pipes of medium inner diameters (5.6 mm and 7 mm), are presented. A low viscosity paraffin oil (4.5 × 10⁻³ Pa s viscosity and 818.5 kg m⁻³ density at 20 °C), deionised water and air are flowing concurrently in Schott Duran^® glass pipes. A decreasing pipe diameter changes the flow pattern maps and also the behavior of the transition boundaries. Flow patterns are determined by high speed photography. To illuminate the pipe, laser induced fluorescence (LIF) is applied. The laser sheet is cutting through the axial vertical plane of the pipe. The laser light excites a fluorescent dye (uranine) in the water phase to separate the phases optically. The resulting flow maps are compared with literature data and a theoretical model.     

Crystal plasticity-based forming limit prediction for non-cubic metals: Application to Mg alloy AZ31B

A viscoplastic crystal plasticity model is incorporated within the Marciniak–Kuczynski (M–K) approach for forming limit curve prediction. The approach allows for the incorporation of crystallographic texture-induced anisotropy and the evolution of the same. The effects of mechanical twinning on the plastic response and texture evolution are also incorporated. Grain-level constitutive parameters describing the temperature dependent behavior of hexagonal close packed Mg alloy, AZ31B, sheets at discrete temperatures are used as a first application of the model. A trade-off between significant strain hardening behavior at lower temperatures (∼150 °C), and significant strain rate hardening at higher temperatures (∼200 °C) lead to similarities in the predicted forming limits. The actual formability of this alloy depends strongly on temperature within this range, and this distinction with the current modeling is related to more localized instability-based failure mechanisms at the lower temperatures than is assumed in the M–K approach. It is shown that the strain path dependence in the strain hardening response is significant and that it influences the forming limits in a predictable way. For broader applicability, a means of incorporating dynamic recrystallization into the crystal plasticity model is required.     

Strength criterion and elastoplastic constitutive model of frozen silt in generalized plastic mechanics

Triaxial compressive tests of frozen silt were carried out under confining pressures from 0.0 to 14.0 MPa at the temperatures of −2, −4 and −6 °C. A strength criterion based upon experimental results is presented by the combination of extended Lade–Duncan strength function f_π(θ) in π-plane and f_p–q(p) in p–q-plane. In order to describe the deformation characteristic of frozen silt, an elastoplastic constitutive model in generalized plastic mechanics has been proposed for the nonlinear behavior of frozen silt, such as the pressure melting and crushing phenomena, strain softening/hardening characteristics and dilatation, etc., by employing an elliptical yield surface, together with a non-associated flow rule for the compressive mechanism, and two parabolic yield surfaces, together with non-associated flow rules for the shear mechanism. The validity of the model is verified by comparing its modeling results with the results of triaxial compressive tests. It is found that the stress–strain curves predicted by this model agree well with the corresponding experimental results both under low and high confining pressures.     

A constitutive equation for filled rubber under cyclic loading

This paper describes experiments and the development of constitutive equations to predict the steady-state response of filled rubber under cyclic loading. An MTS servo-hydraulic machine was used to obtain the dynamic hysteresis curves for a filled rubber compound in uniaxial tension-compression. The material tests were performed with mean strains from −0.1 to 0.1, strain amplitudes ranging from 0.02 to 0.1, and strain rates between 0.01 and 10 s⁻¹. Temporary material set, the Payne effect and rate-dependence were observed from the experimental results. A hyper-viscoelastic constitutive model was developed to characterize the dynamic response of the rubber. A cornerstone of this constitutive modeling was to devise a scheme to evaluate material set and a finite strain, non-linear viscoelastic law from the test data. Predictions of the dynamic hysteresis curves using the proposed constitutive equation were found to be in good agreement with the uniaxial test results.     

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.