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.     

High Strain Rate Torsion Properties of Ultrafine-Grained Aluminum

Mechanical properties of most metallic materials can be improved by reducing their grain size. One of the methods used to reduce the grain size even to the nanometer level is the severe plastic deformation processing. Equal Channel Angular Pressing (ECAP) is one of the most promising severe plastic deformation processes for the nanocrystallization of ductile metals. Nanocrystalline and ultrafine grained metals usually have significantly higher strength properties but lower tensile ductility compared to the coarse grained metals. In this work, the torsion properties of ECAP processed ultrafine grained pure 1070 aluminum were studied in a wide range of strain rates using both servohydraulic materials testing machines and Hopkinson Split Bar techniques. The material exhibits extremely high ductility in torsion and the specimens did not fail even after 300% of strain. Pronounced yield point behavior was observed at strain rates 500 s⁻¹ and higher, whereas at lower strain rates the yielding was continuous. The material showed slight strain softening at the strain rate of 10⁻⁴ s⁻¹, almost ideally plastic behavior at strain rates between 10⁻³ s⁻¹ and 500 s⁻¹, and slight but increasing strain hardening at strain rates higher than that. The tests were monitored using digital cameras, and the strain distributions on the surface of the specimens were calculated using digital image correlation. The strain in the specimen localized very rapidly after yielding at all strain rates, and the localization lead to the development of a shear band. At high strain rates the shear band developed faster than at low strain rates.     

QUASI－FLOW CORNER THEORY ON LARGE PLASTIC DEFORMATION OF DUCTILE METALS AND ITS APPLICATIONS

ＱＵＡＳＩ－ＦＬＯＷＣＯＲＮＥＲＴＨＥＯＲＹＯＮＬＡＲＧＥＰＬＡＳＴＩＣＤＥＦＯＲＭＡＴＩＯＮＯＦＤＵＣＴＩＬＥＭＥＴＡＬＳＡＮＤＩＴＳＡＰＰＬＩＣＡＴＩＯＮＳＨｕＰｉｎｇ（胡平）ＬｉｕＹｕｑｉ（柳玉启）ＧｕｏＷｅｉ（郭威）ＴａｉＦｅｎｇ（台风）（Ｒ...     

Failure prediction in anisotropic sheet metals under forming operations with consideration of rotating principal stretch directions

An approximate macroscopic yield criterion for anisotropic porous sheet metals is adopted to develop a failure prediction methodology that can be used to investigate the failure of sheet metals under forming operations. Hill's quadratic anisotropic yield criterion is used to describe the matrix normal anisotropy and planar isotropy. The approximate macroscopic anisotropic yield criterion is a function of the anisotropy parameter R, defined as the ratio of the transverse plastic strain rate to the through-thickness plastic strain rate under in-plane uniaxial loading conditions. The Marciniak–Kuczynski approach is employed here to predict failure/plastic localization by assuming a slightly higher void volume fraction inside randomly oriented imperfection bands in a material element of interest. The effects of the anisotropy parameter R, the material/geometric inhomogeneities, and the potential surface curvature on failure/plastic localization are first investigated. Then, a non-proportional deformation history including relative rotation of principal stretch directions is identified in a critical element of a mild steel sheet under a fender forming operation given as a benchmark problem in the 1993 NUMISHEET conference. Based on the failure prediction methodology, the failure of the critical sheet element is investigated under the non-proportional deformation history. The results show that the gradual rotation of principal stretch directions lowers the failure strains of the critical element under the given non-proportional deformation history.     

A Finite Element Analysis of a Tapered Flat Sheet Tensile Specimen

A uniaxial tension sheet metal coupon with a tapered instead of a straight gage section has been used for centering the location of diffuse neck and for measuring sheet stretchability in a non-uniform strain field. A finite element analysis of such a tensile coupon made of automotive steel sheet metals has been carried out to assess the effect of the tapered gage section geometry and material plastic strain hardening characteristics on the development of local plastic deformation pattern and local stress state, especially beyond the onset of diffuse necking but before localized necking. In particular, the finite element analysis was used in this study to evaluate the accuracy and reliability of an experimental data analysis method for estimating the post-necking effective plastic stress-strain curve based on the direct local surface axial plastic strain measurements for base metal, heat-affected zone, and weld metals of a dual-phase steel DP600. It is concluded that the estimated lower and upper bounds of the effective stress-strain curve at large strains are not satisfactory for low strain-hardening materials such as heat-affected zone and weld metals with the tapered tension coupons. A simple correction method utilizing only the additional local surface strain measurement in the transverse direction is proposed and it is shown to be effective in correcting the estimated effective stress-strain curve of dual-phase steel weld metals obtained for two tapered gage section geometries.     

An efficient constitutive model for room-temperature,low-rate plasticity of annealed Mg AZ31B sheet

Metals and alloys with hexagonal close packed (HCP) crystal structures can undergo twinning in addition to dislocation slip when loaded mechanically. The complexity of the plastic response and the limited extent of twinning are impediments to their room-temperature formability and thus their widespread adoption. In order to exploit the unusual deformation characteristics of twinning sheet materials in designing novel forming operations, a practical plane stress material model for finite element implementation was sought. Such a model, TWINLAW, has been constructed based on three phenomenological deformation modes for Mg AZ31B: S (slip), T (twinning), and U (untwinning). The modes correspond to three testing regimes: initial in-plane tension (from the annealed state), initial in-plane compression, and in-plane tension following compression, respectively. A von Mises yield surface with initial non-zero back stress was employed to account for plastic yielding asymmetry, with evolution according to a novel isotropic and nonlinear kinematic hardening model. Texture and its evolution were represented throughout deformation using a weighted discrete probability density function of c-axis orientations. The orientation of c-axes evolves with twinning or untwinning using explicit rules incorporated in the model.     

A perturbation analysis of the unstable plastic flow pattern evolution in an aluminum alloy

In the tensile loading of sheet metals made from some polycrystalline aluminum alloys, a single deformation band appears inclined to the elongation axis in the early stage of deformation, and symmetric double bands are observed in the later stage. This evolution of spatial characteristics of such an unstable plastic flow pattern in a polycrystalline aluminum alloy has been analyzed by a perturbation method. A small number of slip modes are taken to describe the tensile strain. A rate-dependent constitutive equation is used for each slip mode to account for the interaction between dislocations and solute atoms in dynamic strain aging. Unconstrained and constrained models are used to impose appropriate loading conditions at the early and later deformation stages, respectively. Both plane-strain and plane-stress cases are considered. It is found out that the change of boundary conditions and material inhomogeneity during the course of plastic deformation are closely related to the evolution of spatial characteristics of shear band (the Portevin–Le Chatelier band) patterns observed in experiments.     

A Study of Large Plastic Deformations in Dual Phase Steel Using Digital Image Correlation and FE Analysis

Large plastic deformation in sheets made of dual phase steel DP800 is studied experimentally and numerically. Shear testing is applied to obtain large plastic strains in sheet metals without strain localisation. In the experiments, full-field displacement measurements are carried out by means of digital image correlation, and based on these measurements the strain field of the deformed specimen is calculated. In the numerical analyses, an elastoplastic constitutive model with isotropic hardening and the Cockcroft–Latham fracture criterion is adopted to predict the observed behaviour. The strain hardening parameters are obtained from a standard uniaxial tensile test for small and moderate strains, while the shear test is used to determine the strain hardening for large strains and to calibrate the fracture criterion. Finite Element (FE) calculations with shell and brick elements are performed using the non-linear FE code LS–DYNA. The local strains in the shear zone and the nominal shear stress-elongation characteristics obtained by experiments and FE simulations are compared, and, in general, good agreement is obtained. It is demonstrated how the strain hardening at large strains and the Cockcroft–Latham fracture criterion can be calibrated from the in-plane shear test with the aid of non-linear FE analyses. An erratum to this article can be found at     

A plane stress anisotropic plastic flow theory for orthotropic sheet metals

A phenomenological theory is presented for describing the anisotropic plastic flow of orthotropic polycrystalline aluminum sheet metals under plane stress. The theory uses a stress exponent, a rate-dependent effective flow strength function, and five anisotropic material functions to specify a flow potential, an associated flow rule of plastic strain rates, a flow rule of plastic spin, and an evolution law of isotropic hardening of a sheet metal. Each of the five anisotropic material functions may be represented by a truncated Fourier series based on the orthotropic symmetry of the sheet metal and their Fourier coefficients can be determined using experimental data obtained from uniaxial tension and equal biaxial tension tests. Depending on the number of uniaxial tension tests conducted, three models with various degrees of planar anisotropy are constructed based on the proposed plasticity theory for power-law strain hardening sheet metals. These models are applied successfully to describe the anisotropic plastic flow behavior of 10 commercial aluminum alloy sheet metals reported in the literature.     

Determination of the Constitutive Relation Parameters of a Metallic Material by Measurement of Temperature Increment in Compressive Dynamic Tests

The mechanical behaviour of a material can be established by an analytic expression called the constitutive relation that shows stress as a function of plastic strain, strain rate, temperature, and possibly other thermo-mechanical variables. The constitutive relation usually includes such parameters as coefficients or exponents that must be determined. At a high strain rate, the heat generated during the deformation process is directly related to the plastic deformation energy of the material. This energy can be calculated from the plastic work, resulting in an expression that includes the constitutive relation parameters as variables. The heat generated can also be estimated by measuring the temperature surface of the specimen during compressive tests using the technique of infrared thermography. The objective of this paper is to present a procedure for determining the constitutive relation parameters by measuring the temperature increase associated with plastic strain in compressive Hopkinson tests. The procedure was applied to estimate the parameters of the Johnson–Cook constitutive relation of an aluminium alloy (Al6082).     

Shear Failure of Inconel 718 under Dynamic Loads

Kinetics of deformation and fracture of nickel–iron alloy Inconel 718 under dynamic shear loading was measured using a split torsional Hopkinson bar facility and high-speed photography. Tubular specimens with a reduced gage length and a starter notch were sheared at strain rates up to 6 × 10³ s⁻¹. High-speed photographs of fiducial lines scribed on the specimen surface showed the development of local strains and cracking. This paper describes the experimental and analytical procedures, illustrates average and local plastic strain evolution, and presents shear crack initiation times and propagation speeds.     

Speckle technique for dynamic drop profile measurement on rough surfaces

A technique has been developed for measuring three-dimensional instantaneous drop profiles on rough surfaces. The surface is illuminated using a laser and images are captured of the resulting speckle pattern with and without the drop in place. The analysis consists of finding the contact line, measuring the deformation of the speckle field caused by refraction of light at the drop surface, then reconstructing the drop using simulated annealing optimization to find the drop shape whose shift vector field best matches the one measured. An error analysis of the technique was performed using a Monte Carlo technique and comparisons to sideview drop images for a large sample of drops. Mean contact angle measurement error was found to be −1.6° with a 1 − σ error bound of −6.9°, +2.0°.     

Types of Localization of Plastic Deformation and Stages of Loading Diagrams of Metallic Materials with Different Crystalline Structures

Macrolocalization, which accompanies the process of plastic deformation beginning from the yield point and ending by fracture, is determined by the staged character of material-loading diagrams. The evolution of localization patterns in a plastic flow of body-centered cubic vanadium alloy, hexagonal close-packed magnesium alloy, tetragonal tin, and face-centered cubic submicrocrystalline aluminum is analyzed within this concept. __________ Translated from Prikladnaya Mekhanika i Tekhnicheskaya Fizika, Vol. 47, No. 2, pp. 176–184, March–April, 2006.     

Residual stresses in turned AISI 4340 steel

The residual-stress distribution in the surface region of workpieces of annealed AISI 4340 steel that is turned under unlubricated conditions is determined using a deflection etching technique. The absolute value of the residual stresses at the machined surface are low and increase with an increase in depth beneath the machined surface to a maximum. They then decrease with a further increase in depth eventually becoming vanishingly small. Peak residual stresses are tensile at cutting speeds of 0.5 and 1.0 ms⁻¹ and are compressive at a cutting speed of 1.5 ms⁻¹ for all feed rates and depths of cut. Peak residual stresses and depth of the stressed region increase with an increase in feed rate and depth of cut, but decrease with an increase in cutting speed. The results of this investigation can be interpreted in terms of the variation of tool forces with cutting conditions.     

On the direct measurement of very large strain at high strain rates

When dynamic plastic strain exceeds 4-percent deformation in completely annealed polycrystalline aluminum, difficulties in the optical measurment of strain occur because of changes in the diffuse-ambient-background light arising from the growth of a mottled surface, or “organe peel.” This paper describes how the diffraction-grating technique may be modified to measure dynamic plastic strain for very large strain at high strain rates in the presence of changing light intensity. The experimental results obtained show that the strain-rate-independent finite-amplitude wave theory, governed by the present writer's generalized, linearly temperature-dependent parabolic stress-strain law, still applies.     

Plastic behavior of a nickel-based alloy under monotonic-tension and low-cycle-fatigue loading

The plastic behavior of an annealed HASTELLOY^® C-22HS™ alloy, a face-centered cubic (FCC), nickel-based superalloy, was examined by in-situ neutron-diffraction measurements at room temperature. Both monotonic-tension and low-cycle-fatigue experiments were conducted. Monotonic-tension straining and cyclic-loading deformation were studied as a function of stress. The plastic behavior during deformation is discussed in light of the relationship between the stress and dislocation-density evolution. The calculated dislocation-density evolution within the alloy reflects the strain hardening and cyclic hardening/softening. Experimentally determined lattice strains are compared to verify the hardening mechanism at selected stress levels for tension and cyclic loadings. Combined with calculations of the dislocation densities, the neutron-diffraction experiments provide direct information about the strain and cyclic hardening of the alloy.     

Constitutive modeling for anisotropic/asymmetric hardening behavior of magnesium alloy sheets

Magnesium alloy sheets have been extending their field of applications to automotive and electronic industries taking advantage of their excellent light weight property. In addition to well-known lower formability, magnesium alloys have unique mechanical properties which have not been thoroughly studied: high in-plane anisotropy/asymmetry of yield stress and hardening response. The reason of the unusual mechanical behavior of magnesium alloys has been understood by the limited symmetry crystal structure of HCP metals and thus by deformation twinning. In this paper, the phenomenological continuum plasticity models considering the unusual plastic behavior of magnesium alloy sheet were developed for a finite element analysis. A hardening law based on two-surface model was further extended to consider the general stress–strain response of metal sheets including Bauschinger effect, transient behavior and the unusual asymmetry. Three deformation modes observed during the continuous in-plane tension/compression tests were mathematically formulated with simplified relations between the state of deformation and their histories. In terms of the anisotropy and asymmetry of the initial yield stress, the Drucker–Prager’s pressure dependent yield surface was modified to include the anisotropy of magnesium alloy. The numerical formulations and characterization procedures were also presented and finally the correlation of simulation with measurements was performed to validate the proposed theory.     

Application of color structured light pattern to measurement of large out-of-plane deformation

Measurement of out-of-plane deformation is significant to understanding of the deflection mechanisms of the plate and tube structures.In this study,a new surface contouring technique with color structured light is applied to measure the out-of-plane deformation of structures with one-shot projection.Through color fringe recognizing,decoding and triangulation processing for the captured images corresponding to each deformation state,the feasibility of the method is testified by the measurement of elastic deflections of a flexible square plate,showing good agreement with those from the calibrated displacement driver.The plastic deformation of two alloy aluminum rectangular tubes is measured to show the technique application to surface topographic evaluation of the buckling structures with large displacements.     

金属塑性变形极限判据

研究出金属材料塑性变形极限判据，它为断裂力学和失效分析提供理论依据。利用这判据，裂纹尖端的临界应变和相应的临界应力可以确定。在板料成形中，拉应力下颈缩失稳的临界应变值可以定出。节省大量试验工作。     

A constitutive relation for pseudo-elastic behaviour in shape memory alloys

A constitutive relation to describe pseudo-elastic deformation in shape memory alloys is presented in this paper. It is capable of describing deformation behaviour of polycrystalline materials under triaxial stress state as well as of monocrystalline materials under one-dimensional condition. Total strain rate is supposed to be composed of elastic strain rate and transformation strain rate. Deformation behaviour of Cu−Zn−Sn alloy and Ti−ni alloy is simulated by use of the proposed constitutive relation. it is shown that simulated results are in a good agreement with experimental data. The project supported by National Natural Science Foundation of China.