Sub-Grain Scale Digital Image Correlation by Electron Microscopy for Polycrystalline Materials during Elastic and Plastic Deformation

Damage during loading of polycrystalline metallic alloys is localized at or below the scale of individual grains. Quantitative assessment of the heterogeneous strain fields at the grain scale is necessary to understand the relationship between microstructure and elastic and plastic deformation. In the present study, digital image correlation (DIC) is used to measure the strains at the sub-grain level in a polycrystalline nickel-base superalloy where plasticity is localized into physical slip bands. Parameters to minimize noise given a set speckle pattern (introduced by chemical etching) when performing DIC in a scanning electron microscope (SEM) were adapted for measurements in both plastic and elastic regimes. A methodology for the optimization of the SEM and DIC parameters necessary for the minimization of the variability in strain measurements at high spatial resolutions is presented. The implications for detecting the early stages of damage development are discussed.     

Agricultural tire deformation in the 2D case by finite element methods

The mechanical characteristics of the rubber tire and the interaction between a tire and a rigid surface were investigated by a two-dimensional (2D) finite element (FE) model. The FE model consists of a rigid rim and a rigid contact surface which interact with the elastic tire. Four distinct sets of elastic parameters are used to represent beads, sidewall, tread and lugs. Several sets of tire loads and inflation pressures were applied to the FE model as boundary conditions, together with various displacements and friction conditions. The deformation of the tire profile, the tire displacements in the vertical and lateral directions, the normal contact pressures, the frictional forces and the stress distribution of the tire components were investigated by the 2D FE model under the above boundary conditions. The calculated tire deflections were compared with the measured data. The results show a good fit between calculated and measured data, especially at high load and inflation pressure. The comparison shows that the FE analysis is suitable to predict aspects of the tire performance like its deflection and interactions with the contact surface. Compared with the experimental methods, the FE methods show many advantages in the prediction of tire deformation, contact pressure and stress distribution.     

Mechanically Regularized FE DIC for Heterogeneous Materials

In situ tensile tests in a scanning electron microscope (SEM) have been conducted on a 8-layer 5-harness satin carbon fibre and epoxy matrix composite to observe the first stages of damage at the scale of fibres and matrix. A speckle pattern based on a suspension of alumina particles was applied onto the surface of the specimen to facilitate the use of digital image correlation (DIC). Local and finite element (FE) DIC are compared on pictures acquired during the tensile tests, with and without a speckle pattern. FE DIC with mechanical regularization was found to be the only approach able to measure displacement fields at a fine enough resolution in both cases. This method, initially created for homogeneous materials, was then adapted to heterogeneous materials. First, a microstructure consistent mesh was created and used for correlation purposes. Second, the difference between the mechanical properties of the constituents is taken into account in the mechanical regularization. Last, the accuracy of the method is analysed. The adaptation presented herein was proved to be able to measure displacement fields in the matrix between fibres with an error of 10 nm (a fifth of a pixel) and to detect the initiation of the first damage mechanisms by means of the mechanical residuals.

     

Realistic Cold Expansion Finite Element Model and Experimental Validations for Aluminium Alloys

Accurate understanding of the residual stresses produced by cold expansion (CX) of rivet holes is required for fatigue considerations, as well as for better addressing the loading problems in aerospace parts. This paper presents a physically based finite element (FE) model for predicting the residual stresses in aluminium parts submitted to CX. The model relies on experimental measurements for both construction and validation purposes. The model predictions were compared against the experimental results delivered by three different complementary techniques: Digital Image Correlation (DIC) (provided strain fields on the surface of the workpiece); X-Ray Diffraction (XRD) (provided residual stresses measurements on the surfaces); Microscopy measurements (measured the out-of-plane displacement on the hole bore). The FE model proves to be in good agreement with the experimental data. Further considerations on the simulation method regarding geometries, boundary conditions and friction effect are also discussed.     

Integration of self-consistent polycrystal plasticity with dislocation density based hardening laws within an implicit finite element framework: Application to low-symmetry metals

We present an implementation of the viscoplastic self-consistent (VPSC) polycrystalline model in an implicit finite element (FE) framework, which accounts for a dislocation-based hardening law for multiple slip and twinning modes at the micro-scale grain level. The model is applied to simulate the macro-scale mechanical response of a highly anisotropic low-symmetry (orthorhombic) crystal structure. In this approach, a finite element integration point represents a polycrystalline material point and the meso-scale mechanical response is obtained by the mean-field VPSC homogenization scheme. We demonstrate the accuracy of the FE-VPSC model by analyzing the mechanical response and microstructure evolution of α-uranium samples under simple compression/tension and four-point bending tests. Predictions of the FE-VPSC simulations compare favorably with experimental measurements of geometrical changes and microstructure evolution. Specifically, the model captures accurately the tension–compression asymmetry of the material associated with twinning, as well as the rigidity of the material response along the hard-to-deform crystallographic orientations.     

Kinematic Field Measurements During Orthogonal Cutting Tests via DIC with Double-frame Camera and Pulsed Laser Lighting

The measurement of machined-part strain fields induced by the cutting process remains a challenge because of the presence of highly intensive and localised strains. In this study, a high-speed double-frame imaging device with pulsed laser lighting is used in order to obtain sharp and highly resolved images during orthogonal cutting tests performed in an aluminium alloy. The displacement fields are then measured using a global Q4–digital-image-correlation (DIC) method and several strategies, facilitating calculation of the total displacements due to the cut, along with the residual strains in the machined part. Numerical procedures are developed to manage the removed material that disturbs the DIC. An automatic primary shear angle detection procedure using DIC is also proposed. Five different markings, which are produced via chemical etching and micro blasting, are applied to the observed surfaces. Their effects on the kinematic fields and the uncertainties are then studied. Three surface parameters are proposed as indicators for determining the surface preparation suitability for the DIC. The repeatability of the kinematic fields induced during the cutting process is studied, because of the ease with which testing can be performed. Finally, the plastically deformed layer engendered by the cutting process is measured using the calculated residual strains.     

Implementation of Convergence in Adaptive Global Digital Image Correlation

In FE based global digital image correlation (DIC) a finite element mesh is used to describe the deformation of the region of interest (ROI). However, the identification of an optimal mesh is a difficult problem and is often obtained by using “mechanical” pre-knowledge of the solution. In Finite Element Analysis (FEA) an optimal mesh can be found without any pre-knowledge of the solution by using mesh adaptivity, where an initial (non optimal) mesh is refined until the optimal solution is obtained. Refinement of the mesh can be based on error and/or convergence estimators. Despite the fundamental differences between FEA and DIC, in the present article the convergence procedure is successfully used in a recently published global FE based DIC method. In the used global DIC method elements can receive higher order shape functions, also known as p-elements. Using the aforementioned algorithm, also called p-DIC, refinement to a non-uniform higher order mesh is possible. Using the non-uniform mesh, an optimal mesh can be obtained for each section of the ROI. The presented study shows that a convergence scheme can be used to automatically control the mesh refinement in a global DIC approach. The convergence boundary, in percentage, is a more intuitive boundary than the absolute error boundary used in the original p-DIC approach. The procedure is validated using numerical examples and the robustness to experimental variables is investigated. Finally, the complete procedure is tested against a wide range of practical examples.     

Dislocation-mediated strain hardening in tungsten: Thermo-mechanical plasticity theory and experimental validation

A self-consistent thermo-mechanical model to study the strain-hardening behavior of polycrystalline tungsten was developed and validated by a dedicated experimental route. Dislocation–dislocation multiplication and storage, as well dislocation-grain boundary (GB) pinning were the major mechanisms underlying the evolution of plastic deformation, thus providing a link between the strain hardening behavior and material's microstructure. The microstructure of the polycrystalline tungsten samples has been thoroughly investigated by scanning and electron microscopy. The model was applied to compute stress–strain loading curves of commercial tungsten grades, in the as-received and as-annealed states, in the temperature range of 500–1000 °C. Fitting the model to the independent experimental results obtained using a single crystal and as-received polycrystalline tungsten, the model demonstrated its capability to predict the deformation behavior of as-annealed samples in a wide temperature range and applied strain. The relevance of the dislocation-mediated plasticity mechanisms used in the model have been validated using transmission electron microscopy examination of the samples deformed up to different amounts of strain. On the basis of the experimental validation, the limitations of the model are determined and discussed.     

Active Slip System Identification in Polycrystalline Metals by Digital Image Correlation (DIC)

In this paper, a novel approach was proposed to increase the confidence of active slip system identification in polycrystalline metals. The approach takes advantage of microscale deformation tracking via Digital Image Correlation (DIC) combined with scanning electron microscopy (SEM). The experimentally-obtained high-resolution deformation fields were mapped to an undeformed configuration, which gives slip traces suitable for comparison with undeformed crystal orientation data. A metric, named herein as the ‘relative displacement ratio’ (RDR), is calculated from the displacement fields near slip traces to characterize the localized deformation due to slip. In validation cases, the experimentally-measured RDRs matched well with RDRs theoretically-calculated from active slip systems. In test cases, active slip system identification by incorporating RDR as an additional constraint was demonstrated to be preferable to using Schmid factor alone as a constraint. The proposed approach supplements existing techniques for slip system identification with increased confidence.     

A representative volume element based on translational symmetries for FE analysis of cracked laminates with two arrays of cracks

A methodology is proposed for the construction of a representative volume element (RVE) for analysis of laminated composites containing two arrays of ply cracks running in different directions. The only requirement is that the cracks in any ply are uniformly spaced, and if more than one ply of a given orientation is cracked, then the crack spacing of individual plies must only be in exact multiples of each other. The spacing of cracks in the two directions can be fully independent. The RVE is constructed through a systematic consideration of translational symmetries present in the cracked laminate. As a result, the boundary conditions on the RVE can be imposed without compromising accuracy. Examples of the application of the RVE methodology are given to illustrate its broad capability and a finite element (FE) stress analysis is performed for these cases to illustrate results such as the crack surface displacements, local stress fields and RVE-averaged elastic properties. For one case, the average properties are compared with experimental results, showing good agreement.     

3-D simulation of spatial stress distribution in an AZ31 Mg alloy sheet under in-plane compression

A complete 3-D crystal plasticity finite element method (CPFEM) that considered both crystallographic slip and deformation twinning was applied to simulate the spatial distribution of the relative amount of slip and twin activities in a polycrystalline AZ31 Mg alloy during in-plane compression. A microstructure mapping technique that considered the grain size distribution and microtexture measured by electron backscatter diffraction (EBSD) technique was used to create a statistically representative 3-D microstructure for the initial configuration. Using a 3-D Monte Carlo method, a 3-D digital microstructure that matched the experimentally measured grain size distribution was constructed. Crystallographic orientations obtained from the EBSD data were assigned on the 3-D digital microstructure to match the experimentally measured misorientation distribution. CPFEM captured the heterogeneity of the stress concentration as well as the slip and twin activities of a polycrystalline AZ31 Mg alloy during in-plane compression.     

Study of the antiplane deformation of linear 2-D polycrystals with different microstructures

The effective behavior and the distribution of local mechanical fields of linearly viscous 2-D polycrystals under antiplane shear is investigated. Several microstructures are considered, and a full-field approach based on the Fast Fourier Transform technique is applied. First, the accuracy of this technique is evaluated on a strictly isotropic 2-phase microstructure. Voronoi tessellation is then used to generate artificial microstructures, and a real (fully recrystallized) polycrystalline microstructure is obtained by electron back-scattering diffraction. Ensemble averages over several configurations using eight crystalline orientations (phases) are performed. Although a slight anisotropy is obtained for the effective behavior of each individual configuration, statistically, the results are in very good agreement with the available analytical isotropic solution. At phase level, a marked asymmetry is obtained for the distribution of local stresses. The intraphase first- and second-order moments of the stress field, calculated for both microstructures are compared with corresponding self-consistent predictions.     

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.     

Use of 3-D Digital Image Correlation to Characterize the Mechanical Behavior of a Fiber Reinforced Refractory Castable

Refractory castables exhibit very low fracture strain levels when subjected to tension or bending. The main objective of this work is to show that 3-D digital image correlation (3-D DIC) allows such low strain levels to be measured. Compared to mechanical extensometer measurements, 3-D DIC makes it possible to reach similar strain resolution levels and to avoid the problem of position dependance related to the heterogeneous nature of the strain and to strain localization phenomena. First, the 3-D DIC method and the experimental set-up are presented. Secondly, an analysis of the 3-D DIC method is performed in order to evaluate the resolution, the standard uncertainty and the spatial resolution for both displacement and strain measurements. An optimized compromise between strain spatial resolution and standard uncertainty is reached for the configuration of the experimental bending test. Finally, the macroscopic mechanical behavior of a fiber reinforced refractory castable (FRRC) is studied using mechanical extensometry and 3-D DIC in the case of tensile and four-point bending tests. It is shown that similar results are obtained with both methods. Furthermore, in the case of bending tests on damaged castable, 3-D DIC results demonstrate the ability to determine Young’s modulus from heterogeneous strain fields better than by using classical beam deflection measurements.     

Quantitative Strain Analysis of the Large Deformation at the Scale of Microstructure: Comparison between Digital Image Correlation and Microgrid Techniques

A comparative study has been carried out to assess the accuracy of the Digital Image Correlation (DIC) technique for the quantification of large strains in the microstructure of an Interstitial Free (IF) steel used in automotive applications. A microgrid technique has been used in this study in order to validate independently the strain measurements obtained with DIC. Microgrids with a pitch of 5 microns were printed on the etched microstructure of the IF steel to measure the local in-plane strain distribution during a tensile test carried out in a Scanning Electron Microscope (SEM). The progressive deformation of the microstructure with microgrids has been recorded throughout the test as a sequence of micrographs and subsequently processed using DIC to quantify the distribution of local strain values. Strain maps obtained with the two techniques have been compared in order to assess the accuracy of the DIC measurements obtained using the natural patterns of the revealed microstructure in the SEM micrographs. The results obtained with the two techniques are qualitatively similar and thus, demonstrate the reliability of DIC applied to microstructures, even after large deformations in excess of 0.7. However, an average error of about 16?% was found in the strain values calculated using DIC.     

Strain Mapping of Al–Mg Alloy with Multi-scale Grain Structure using Digital Image Correlation Method

Al–Mg alloy powder was mechanically milled in liquid N₂ (cryomilling) to produce thermally stable powder with nanocrystalline (NC) microstructure for the manufacture of high-strength alloys. A multi-scale microstructure was achieved by blending unmilled coarse-grained (CG) powder with cryomilled powder and subsequently consolidating. The final bulk alloy was comprised of ultra-fine grained (UFG) regions and discrete CG bands. Dynamic observations of tensile deformation of the alloy were recorded using a micro-straining module attached to a light microscope, and the displacements were measured by digital image correlation (DIC). Strain inhomogeneity between UFG regions and ductile CG bands was observed in the micro-strain (strain order of 10⁻⁴–10⁻⁶) range, and the strain behavior was interpreted in terms of dislocation plasticity. Special emphasis was given to the distinct displacements between adjoining regions during deformation.     

Grain Boundary Sliding and Slip Transmission in High Purity Aluminum

Despite its significance in polycrystalline materials, there have been few experimental investigations of the activity of grain boundary sliding (GBS) and the relationship between GBS and slip transmission at grain boundaries. The present work addresses this knowledge gap by the characterization of full-field strain and microstructural information in an experimental system of high-purity (99.99%) columnar aluminum subjected to uniaxial tension at 190 °C. High-resolution, full-gage strain fields were characterized on an unloaded specimen by distortion-corrected and stitched scanning electron microscope-enabled digital image correlation (SEM-DIC). Alignment between the lower-resolution electron backscatter diffraction (EBSD) and higher-resolution strain fields was significantly improved by clustering of strain data within an EBSD-defined boundary mantle. Grain boundary sliding was investigated at select boundaries, and it was determined that GBS magnitude profiles can have large gradients along a single boundary and vary significantly between boundaries. Using a geometric compatibility factor (m′) to quantify favorability of slip transmission, the two grain boundaries that exhibited the largest average GBS magnitude experienced contiguous slip on moderately well aligned slip systems, although the exact nature of this slip activity, whether transmission or nucleation, remains under investigation.

     

A continuum model for size-dependent deformation of elastic films of nano-scale thickness

Ultra-thin elastic films of nano-scale thickness with an arbitrary geometry and edge boundary conditions are analyzed. An analytical model is proposed to study the size-dependent mechanical response of the film based on continuum surface elasticity. By using the transfer-matrix method along with an asymptotic expansion technique of small parameter, closed-form solutions for the mechanical field in the film is presented in terms of the displacements on the mid-plane. The asymptotic expansion terminates after a few terms and exact solutions are obtained. The mid-plane displacements are governed by three two-dimensional equations, and the associated edge boundary conditions can be prescribed on average. Solving the two-dimensional boundary value problem yields the three-dimensional response of the film. The solution is exact throughout the interior of the film with the exception of a thin boundary layer having an order of thickness as the film in accordance with the Saint-Venant’s principle.     

球形压痕的残余变形分析

球形压痕技术在材料力学属性，诸如硬度，弹性模量等的测量中得到了广泛的应用。应用Twyman-Green及云纹干涉法并配合相移技术，本文对IN783合金进行了一系列的球形压痕实验研究，并对残余压痕的面内（u,v）及离面（w）变形场进行了定量测量和分析。应用面内变形测量结果，进一步对试件表面的应力一应变分布进行了分析和计算，并在离面变形场的基础上，确立了压痕周围的弹塑性边界，从而进一步应用面内的分析结果，得到材料的屈服强度。应用压痕实验的接触半径和压力并配合Tabor经验公式，本文进一步得到了材料的应力应变曲线。实验结果与已知的IN783合金相吻合。对所涉及的一系列压痕实验，本文也进行了二维有限元分析并得到了比较一致的结果。