The size effect on void growth in ductile materials

We have extended the Rice-Tracey model (J. Mech. Phys. Solids 17 (1969) 201) of void growth to account for the void size effect based on the Taylor dislocation model, and have found that small voids tend to grow slower than large voids. For a perfectly plastic solid, the void size effect comes into play through the ratio εl/R₀, where l is the intrinsic material length on the order of microns, ε the remote effective strain, and R₀ the void size. For micron-sized voids and small remote effective strain such that εl/R₀?0.02, the void size influences the void growth rate only at high stress triaxialities. However, for sub-micron-sized voids and relatively large effective strain such that εl/R₀>0.2, the void size has a significant effect on the void growth rate at all levels of stress triaxiality. We have also obtained the asymptotic solutions of void growth rate at high stress triaxialities accounting for the void size effect. For εl/R₀>0.2, the void growth rate scales with the square of mean stress, rather than the exponential function in the Rice-Tracey model (1969). The void size effect in a power-law hardening solid has also been studied.     

Coupling effects of void size and void shape on the growth of prolate ellipsoidal microvoid

The combined effects of void size and void shape on the void growth are studied by using the classical spectrum method. An infinite solid containing an isolated prolate spheroidal void is considered to depict the void shape effect and the Fleck-Hutchinson phenomenological strain gradient plasticity theory is employed to capture the size effects. It is found that the combined effects of void size and void shape are mainly controlled by the remote stress triaxiality. Based on this, a new size-dependent void growth model similar to the Rice-Tracey model is proposed and an important conclusion about the size-dependent void growth is drawn: the growth rate of the void with radius smaller than a critical radius r_c may be ignored. It is interesting that r_c is a material constant independent of the initial void shape and the remote stress triaxiality.The project supported by the National Natural Science Foundation of China (A10102006) and the New Century Excellent Talents in Universities of China. The English text was polished by Keren Wang.     

Strain gradient effects on cyclic plasticity

Size effects on the cyclic shear response are studied numerically using a recent higher order strain gradient visco-plasticity theory accounting for both dissipative and energetic gradient hardening. Numerical investigations of the response under cyclic pure shear and shear of a finite slab between rigid platens have been carried out, using the finite element method. It is shown for elastic-perfectly plastic solids how dissipative gradient effects lead to increased yield strength, whereas energetic gradient contributions lead to increased hardening as well as a Bauschinger effect. For linearly hardening materials it is quantified how dissipative and energetic gradient effects promote hardening above that of conventional predictions. Usually, increased hardening is attributed to energetic gradient effects, but here it is found that also dissipative gradient effects lead to additional hardening in the presence of conventional material hardening. Furthermore, it is shown that dissipative gradient effects can lead to both an increase and a decrease in the dissipation per load cycle depending on the magnitude of the dissipative length parameter, whereas energetic gradient effects lead to decreasing dissipation for increasing energetic length parameter. For dissipative gradient effects it is found that dissipation has a maximum value for some none zero value of the material length parameter, which depends on the magnitude of the deformation cycles.     

Size effects under homogeneous deformation of single crystals: A discrete dislocation analysis

Mechanism-based discrete dislocation plasticity is used to investigate the effect of size on micron scale crystal plasticity under conditions of macroscopically homogeneous deformation. Long-range interactions among dislocations are naturally incorporated through elasticity. Constitutive rules are used which account for key short-range dislocation interactions. These include junction formation and dynamic source and obstacle creation. Two-dimensional calculations are carried out which can handle high dislocation densities and large strains up to 0.1. The focus is laid on the effect of dimensional constraints on plastic flow and hardening processes. Specimen dimensions ranging from hundreds of nanometers to tens of microns are considered. Our findings show a strong size-dependence of flow strength and work-hardening rate at the micron scale. Taylor-like hardening is shown to be insufficient as a rationale for the flow stress scaling with specimen dimensions. The predicted size effect is associated with the emergence, at sufficient resolution, of a signed dislocation density. Heuristic correlations between macroscopic flow stress and macroscopic measures of dislocation density are sought. Most accurate among those is a correlation based on two state variables: the total dislocation density and an effective, scale-dependent measure of signed density.     

Size effects in the constrained deformation of metallic foams

The constrained deformation of an aluminium alloy foam sandwiched between steel substrates has been investigated. The sandwich plates are subjected to through-thickness shear and normal loading, and it is found that the face sheets constrain the foam against plastic deformation and result in a size effect: the yield strength increases with diminishing thickness of foam layer. The strain distribution across the foam core has been measured by a visual strain mapping technique, and a boundary layer of reduced straining was observed adjacent to the face sheets. The deformation response of the aluminium foam layer was modelled by the elastic-plastic finite element analysis of regular and irregular two dimensional honeycombs, bonded to rigid face sheets; in the simulations, the rotation of the boundary nodes of the cell-wall beam elements was set to zero to simulate full constraint from the rigid face sheets. It is found that the regular honeycomb under-estimates the size effect whereas the irregular honeycomb provides a faithful representation of both the observed size effect and the observed strain profile through the foam layer. Additionally, a compressible version of the Fleck-Hutchinson strain gradient theory was used to predict the size effect; by identifying the cell edge length as the relevant microstructural length scale the strain gradient model is able to reproduce the observed strain profiles across the layer and the thickness dependence of strength.     

Cylindrical void in a rigid-ideally plastic single crystal III: Hexagonal close-packed crystal

The analytical solution is derived for the plane strain stress field around a cylindrical void in a hexagonal close-packed single crystal with three in-plane slip systems oriented at the angle π/3 with respect to one another. The critical resolved shear stress on each slip system is assumed to be equal. The crystal is loaded by both internal pressure and a far-field equibiaxial compressive stress. The deformation field takes the form of angular sectors, called slip sectors, within which only one slip system is active; the boundaries between different sectors are radial lines. The stress fields are derived by enforcing equilibrium and a rigid, ideally plastic constitutive relationship, in the spirit of anisotropic slip line theory. The results show that each slip sector is divided into smaller regions denoted as stress sectors and the stress state valid within each stress sector is derived. It is shown that stresses are unique and are continuous within stress sectors and across stress sector boundaries, but the gradient of stresses is not continuous across the boundaries between stress sectors. The solution shows self-similarity in that the stresses over the entire domain can be determined from the stresses within a small region adjacent to the void by invoking certain scaling and symmetry properties. In addition, the stress state exhibits periodicity along logarithmic spirals which emanate from the void. The results predict that the mean value of in-plane pressure required to activate plastic deformation around a void in a single crystal can be higher than that necessary for a void in an isotropic material and is sensitive to the orientation of the slip systems relative to the void.     

A yield function for single crystals containing voids

A yield function for single crystals containing voids has been developed based on a variational approach. This first yield function is phenomenologically extended by modifying the dependence on the mean stress and introducing three adjustable parameters. Unit cell finite element calculations are performed for various stress triaxiality ratios, main loading directions and porosity levels in the case of a perfectly plastic FCC single crystal. The three model parameters are adjusted on the unit cell calculations so that a very good agreement between simulation results and the proposed model is obtained.     

A cyclic plasticity model for single crystals

The Armstrong–Frederick type kinematic hardening rule was invoked to capture the Bauschinger effect of the cyclic plastic deformation of a single crystal. The yield criterion and flow rule were built on individual slip systems. Material memory was introduced to describe strain range dependent cyclic hardening. The experimental results of copper single crystals were used to evaluate the cyclic plasticity model. It was found that the model was able to accurately describe the cyclic plastic deformation and properly reflect the dislocation substructure evolution. The well-known three distinctive regimes in the cyclic stress–strain curve of the copper single crystals oriented for single slip can be reproduced by using the model. The model can predict the enhanced hardening for crystals oriented for multislip, showing the model's ability to describe anisotropic cyclic plasticity. For a given loading history, the model was able to capture not only the saturated stress–strain response but also the detailed transient stress–strain evolution. The model was used to predict the cyclic plasticity under a high–low loading sequence. Both the stress–strain responses and the microstructural evolution can be appropriately described through the slip system activation.     

Bending of single crystal microcantilever beams of cube orientation: Finite element model and experiments

The aim of this work is to investigate the microstructure evolution, stress-strain response and strain hardening behavior of microscale beams. For that purpose, two single crystal cantilever beams in the size dependent regime were manufactured by ion beam milling and beams were bent with an indenter device. A crystal plasticity material model for large deformations was implemented in a finite element framework to further investigate the effect of boundary constraints. Simulations were performed using bulk material properties of single crystal copper without any special treatment for the strain gradients. The difference between the slopes of the experimental and the simulated force displacement curves suggested negligible amount of strain gradient hardening compared to the statistical hardening mechanisms.     

Size effects due to secondary voids during ductile crack propagation

In the present study the size-effect due to a secondary void population during ductile fracture is investigated. Discrete primary voids are resolved in the process zone at the crack tip. A non-local GTN model is employed to describe the evolution of the secondary voids in the intervoid ligaments. The non-local GTN model contains an intrinsic length scale related to the size of the secondary voids. Hence, the ratio of the size of the primary and that of the secondary voids can be varied. The results show that small secondary voids can toughen the material. Such a behavior is in contrast to the prediction of cell model simulations. A theoretical reasoning of this effect and conclusions are given.     

Plasticity size effects in tension and compression of single crystals

The effect of size and loading conditions on the tension and compression stress-strain response of micron-sized planar crystals is investigated using discrete dislocation plasticity. The crystals are taken to have a single active slip system and both small-strain and finite-strain analyses are carried out. When rotation of the tensile axis is constrained, the build-up of geometrically necessary dislocations results in a weak size dependence but a strong Bauschinger effect. On the other hand, when rotation of the tensile axis is unconstrained, there is a strong size dependence, with the flow strength increasing with decreasing specimen size, and a negligible Bauschinger effect. Below a certain specimen size, the flow strength of the crystals is set by the nucleation strength of the initially present Frank-Read sources. The main features of the size dependence are the same for the small-strain and finite-strain analyses. However, the predicted hardening rates differ and the finite-strain analyses give rise to some tension-compression asymmetry.     

A novel yield function for single crystals based on combined constraints optimization

A novel yield function representing the overall plastic deformation in a single crystal is developed using the concept of optimization. Based on the principle of maximum dissipation during a plastic deformation, the problem of single crystal plasticity is first considered as a constrained optimization problem in which constraints are yield functions for slip systems. To overcome the singularity that usually arises in solving the above problem, a mathematical technique is used to replace the above constrained optimization problem with an equivalent problem which has only one constraint. This single constraint optimization problem, the so-called combined constraints crystal plasticity (CCCP) model, is implemented into a finite element code and the results of modeling the uniaxial tensions of the single crystal copper along different crystallographic directions and also hydroforming of aluminum tubes proved the capability of the proposed CCCP model in accurately predicting the deformation in polycrystalline materials.     

Size effects in generalised continuum crystal plasticity for two-phase laminates

The solutions of a boundary value problem are explored for various classes of generalised crystal plasticity models including Cosserat, strain gradient and micromorphic crystal plasticity. The considered microstructure consists of a two-phase laminate containing a purely elastic and an elasto-plastic phase undergoing single or double slip. The local distributions of plastic slip, lattice rotation and stresses are derived when the microstructure is subjected to simple shear. The arising size effects are characterised by the overall extra back stress component resulting from the action of higher order stresses, a characteristic length l_c describing the size-dependent domain of material response, and by the corresponding scaling law lⁿ as a function of microstructural length scale, l. Explicit relations for these quantities are derived and compared for the different models. The conditions at the interface between the elastic and elasto-plastic phases are shown to play a major role in the solution. A range of material parameters is shown to exist for which the Cosserat and micromorphic approaches exhibit the same behaviour. The models display in general significantly different asymptotic regimes for small microstructural length scales. Scaling power laws with the exponent continuously ranging from 0 to −2 are obtained depending on the values of the material parameters. The unusual exponent value −2 is obtained for the strain gradient plasticity model, denoted “curl H^p” in this work. These results provide guidelines for the identification of higher order material parameters of crystal plasticity models from experimental data, such as precipitate size effects in precipitate strengthened alloys.     

Wedge indentation into elastic-plastic single crystals. 2: Simulations for face-centered cubic crystals

The asymptotic stress and deformation fields associated with the contact point singularity of a nearly-flat wedge indenter impinging on a specially-oriented single face-centered cubic crystal are derived analytically in a companion paper. In order to investigate the extent of the asymptotic fields, the indentation process is simulated numerically using single crystal plasticity. The quasistatically translating asymptotic fields consist of four angular elastic sectors separated by plastically deforming sector boundaries, as predicted in the companion paper. The asymptotic stress distributions are in accord with the analytical predictions. In addition, simulations are performed for a wedge indenter with a 90° included angle in order to investigate the consequences of finite deformation and finite lattice rotation. Several salient features of the deformation field for the nearly-flat indenter persist in the deformation field for the 90° wedge indenter. The existence of the salient features is validated by comparison to experimental measurements of the lower bound on geometrically necessary dislocation (GND) densities.     

Lattice orientation effects on void growth and coalescence in fcc single crystals

Void growth and coalescence in fcc single crystals were studied using crystal plasticity under uniaxial and biaxial loading conditions and various orientations of the crystalline lattice. A 2D plane strain unit cell with one and two cylindrical voids was employed using three-dimensional 12 potentially active slip systems. The results were compared to five representative orientations of the tensile axis on the stereographic triangle. For uniaxial tension conditions, the void volume fraction increase under the applied load is strongly dependent on the crystallographic orientation with respect to the tensile axis. For some orientations of the tensile axis, such as [1 0 0] or [1 1 0], the voids exhibited a growth rate twice as fast compared with other orientations ([1 0 0], [2 1 1]). Void growth and coalescence simulations under uniaxial loading indicated that during deformation along some orientations with asymmetry of the slip systems, the voids experienced rotation and shape distortion, due mainly to lattice reorientation. Coalescence effects are shown to diminish the influence of lattice orientation on the void volume fraction increase, but noteworthy differences are still present. Under biaxial loading conditions, practically all differences in the void volume fraction for different orientations of the tensile axes during void growth vanish. These results lead to the conclusion that at microstructural length scales in regions under intense biaxiality/triaxiality conditions, such as crack tip or notched regions, the plastic anisotropy due to the initial lattice orientation has only a minor role in influencing the void growth rate. In such situations, void growth and coalescence are mainly determined by the stress triaxiality, the magnitude of accumulated strain, and the spatial localization of such plastic strains.     

Formulation of strain gradient plasticity with interface energy in a consistent thermodynamic framework

In this work, the strain gradient formulation is used within the context of the thermodynamic principle, internal state variables, and thermodynamic and dissipation potentials. These in turn provide balance of momentum, boundary conditions, yield condition and flow rule, and free energy and dissipative energies. This new formulation contributes to the following important related issues: (i) the effects of interface energy that are incorporated into the formulation to address various boundary conditions, strengthening and formation of the boundary layers, (ii) nonlocal temperature effects that are crucial, for instance, for simulating the behavior of high speed machining for metallic materials using the strain gradient plasticity models, (iii) a new form of the nonlocal flow rule, (iv) physical bases of the length scale parameter and its identification using nano-indentation experiments and (v) a wide range of applications of the theory. Applications to thin films on thick substrates for various loading conditions and torsion of thin wires are investigated here along with the appropriate length scale effect on the behavior of these structures. Numerical issues of the theory are discussed and results are obtained using Matlab and Mathematica for the nonlinear ordinary differential equations (NODE) which constitute the boundary value problem.This study reveals that the micro-stress term has an important effect on the development of the boundary layers and hardening of the material at both hard and soft interface boundary conditions in thin films. The interface boundary conditions are described by the interfacial length scale and interfacial strength parameters. These parameters are important to control the size effect and hardening of the material. For more complex geometries the generalized form of the boundary value problem using the nonlocal finite element formulation is required to address the problems involved.     

Dynamic void nucleation and growth in solids: A self-consistent statistical theory

We present a framework for a self-consistent theory of spall fracture in ductile materials, based on the dynamics of void nucleation and growth. The constitutive model for the material is divided into elastic and “plastic” parts, where the elastic part represents the volumetric response of a porous elastic material, and the “plastic” part is generated by a collection of representative volume elements (RVEs) of incompressible material. Each RVE is a thick-walled spherical shell, whose average porosity is the same as that of the surrounding porous continuum, thus simulating void interaction through the resulting lowered resistance to further void growth. All voids nucleate and grow according to the appropriate dynamics for a thick-walled sphere made of incompressible material. The macroscopic spherical stress in the material drives the response in all volume elements, which have a distribution of critical stresses for void nucleation, and the statistically weighted sum of the void volumes of all RVEs generates the global porosity. Thus, macroscopic pressure, porosity, and a distribution of growing microscopic voids are fully coupled dynamically. An example is given for a rate-independent, perfectly plastic material. The dynamics of void growth gives rise to a rate effect in the macroscopic material even though the parent material is rate independent.     

Strain gradient plasticity effects in whisker-reinforced metals

A metal reinforced by fibers in the micron range is studied using the strain gradient plasticity theory of Fleck and Hutchinson (J. Mech. Phys. Solids 49 (2001) 2245). Cell-model analyses are used to study the influence of the material length parameters numerically, for both a single parameter version and the multiparameter theory, and significant differences between the predictions of the two models are reported. It is shown that modeling fiber elasticity is important when using the present theories. A significant stiffening effect when compared to conventional models is predicted, which is a result of a significant decrease in the level of plastic strain. Moreover, it is shown that the relative stiffening effect increases with fiber volume fraction. The higher-order nature of the theories allows for different higher-order boundary conditions at the fiber-matrix interface, and these boundary conditions are found to be of importance. Furthermore, the influence of the material length parameters on the stresses along the interface between the fiber and the matrix material is discussed, as well as the stresses within the elastic fiber which are of importance for fiber breakage.     

On the evolution of crystallographic dislocation density in non-homogeneously deforming crystals

A set of evolution equations for dislocation density is developed incorporating the combined evolution of statistically stored and geometrically necessary densities. The statistical density evolves through Burgers vector-conserving reactions based in dislocation mechanics. The geometric density evolves due to the divergence of dislocation fluxes associated with the inhomogeneous nature of plasticity in crystals. Integration of the density-based model requires additional dislocation density/density-flux boundary conditions to complement the standard traction/displacement boundary conditions. The dislocation density evolution equations and the coupling of the dislocation density flux to the slip deformation in a continuum crystal plasticity model are incorporated into a finite element model. Simulations of an idealized crystal with a simplified slip geometry are conducted to demonstrate the length scale-dependence of the mechanical behavior of the constitutive model. The model formulation and simulation results have direct implications on the ability to explicitly model the interaction of dislocation densities with grain boundaries and on the net effect of grain boundaries on the macroscopic mechanical response of polycrystals.