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At least 649 records · Page 36

Creep Deformation and Dynamic Grain Growth in an Interstitial-Free Steel

Dynamic grain growth is demonstrated to be much faster than static grain growth in a body-centered-cubic, interstitial-free steel sheet material at 850°C. Dynamic grain growth occurs during concurrent plastic deformation at elevated temperature, whereas static grain growth occurs during static annealing. Grain growth during steady-state plastic flow in tension at 850°C to a true strain of 0.2 at a true-strain rate of 10 -4 s -1 doubled grain size, while static annealing for the same time produced no increase in grain size. This is described as dynamic normal grain growth (DNGG) because no abnormally large grains were observed. The recrystallized microstructure of the steel demonstrated a log-normal distribution of grain sizes. DNGG produced bimodal grain size distributions that deviate from the theoretical expectation of a simple shift to larger sizes during normal growth. The bimodal distributions contained a remnant of small grains that were not consumed during grain growth. DNGG produced a crystallographic texture that is unique from both the recrystallized material and that produced by lattice rotation alone. DNGG strengthened the {111}⟨110⟩ and {111}⟨112⟩ components of the strong γ-fiber component in the original recrystallization texture. Lattice rotation from tensile deformation, by contrast, strengthened the α-fiber components that intersect the original γ-fiber.

36 MATERIALS SCIENCE↗

In-Situ Observation of FCC→HCP Transformation-Induced Plasticity Behavior During Dynamic Deformation of CoCrNi Multi-principal Element Alloys

CoCrNi multi-principal element alloys (MPEAs) have potential as high toughness, blast resistant materials, but limited studies of their high strain rate behavior have been performed. Their high toughness has been attributed to low stacking fault energies and the activation of toughness enhancing deformation mechanisms, such as twinning- and transformation-induced plasticity (TWIP and TRIP, respectively), that may be affected by increased strain rate. This work examines a series of CoCrNi MPEAs tested with a miniaturized pressure bar, while simultaneous synchrotron x-ray diffraction and imaging are performed, and compares these results to those collected during quasi-static deformation at elevated temperatures. Here, the collected diffraction indicates that TRIP was active at elevated strain rates for the most Co-rich alloys containing 50 or 55 at. pct. Co, while TRIP behavior was suppressed at elevated strain rates in a 40 at. pct. Co alloy anticipated to experience TRIP. The suppression of TRIP in the lower Co alloy at high strain rates is attributed to adiabatic heating, consistent with suppression of TRIP as a result of elevated temperatures.

36 MATERIALS SCIENCE↗

A Review: Microstructural and Phase Evolution in Alloys during Extended Plastic Deformation

Materials in service and during processing are often subjected to plastic deformation. For multi-phase metallic alloys, simple geometric models and atomistic simulations suggest that two distinctive regimes in these materials’ evolution during deformation exist. At low strains, evolutions are often dominated by the kinetic roughening of interfaces, which results from the superdiffusive transport of matter in sheared crystals. Furthermore, at high strains and temperatures where thermal diffusion is sluggish, on the other hand, shearing- induced forced atomic mixing dominates these evolutions, resulting in significantly enhanced solubility. Distinguishing these two regimes is shown to provide a convenient framework for rationalizing and analyzing recent experiments and simulations on wear of layered structures in the low strain-regime and nonequilibrium phase co-existence and self-organization in highly immiscible or reactive alloy systems in the high-strain regime.

36 MATERIALS SCIENCE↗

Highly deformable Mg–Al–Ca alloy with Al 2 Ca precipitates

Magnesium (Mg) is the lightest structural metal. However, the poor formability of Mg alloys to great extent limits their applications in making structural parts. Formability is strongly correlated to both high tensile elongation and large work hardening capacity. In this work, we report a new Mg-Al-Ca alloy in which a majority of deformable Al 2 Ca precipitates form while the formation of Laves phases of Mg 17 Al 12 and Mg 2 Ca seems suppressed. Al 2 Ca precipitates imped dislocation motion, leading to large work hardening. Then, Al 2 Ca precipitates deform with dislocations and stacking faults under the enhanced flow stress, which relieve local stress concentration and improve tensile elongation. In addition, solutes Al and Ca suppress twin nucleation while promoting non-basal dislocations in Mg. Our Mg-Al-Ca alloy demonstrates one of the highest combinations of tensile elongation and work hardening capacity among existing Mg alloys.

36 MATERIALS SCIENCE↗

Pseudoelastic deformation in Mo-based refractory multi-principal element alloys

Phase diagrams supported by density functional theory methods can be crucial for designing high-entropy alloys that are subset of multi-principal-element alloys. We present phase and property analysis of quinary (MoW) x Zr y (TaTi) 1-x-y refractory high-entropy alloys from combined Calculation of Phase Diagram (CALPHAD) and density-functional theory results, supplemented by molecular dynamics simulations. Both CALPHAD and density-functional theory analysis of phase stability indicates a Mo-W-rich region of this quinary has a stable single-phase body-centered-cubic structure. We report first quinary composition from Mo-W-Ta-Ti-Zr family of alloy with pseudo-elastic behavior, i.e., hysteresis in stress-strain. Our analysis shows that only Mo-W-rich compositions of Mo-W-Ta-Ti-Zr, i.e., Mo+W, show reproducible hysteresis in stress-strain responsible for pseudo-elastic behavior. The (MoW) 85 Zr 7.5 (TaTi) 7.5 was down-selected based on temperature-dependent phase diagram analysis and molecular dynamics simulations predicted elastic behavior that reveals twinning-assisted pseudoelastic behavior. While mostly unexplored in body-centered-cubic crystals, twinning is a fundamental deformation mechanism that competes against dislocation slip in crystalline solids. Furthermore, this alloy shows identical cyclic deformation characteristics during uniaxial < 100 > loading, i.e., the pseudoelasticity is isotropic in loading direction. Additionally, a temperature increase from 77 to 1,500 K enhances the elastic strain recovery in load-unload cycles, offering possibly control to tune the pseudoelastic behavior.

36 MATERIALS SCIENCE↗

Load shuffling during creep deformation of an additively manufactured AlCuMnZr alloy

Here, the high-temperature deformation behavior of an additively manufactured Al-Cu-Mn-Zr alloy is evaluated in the as-fabricated and heat-treated states using traditional ex-situ and in-situ neutron diffraction creep experiments performed at 300 °C. The dominant reinforcement phase in the alloy, θ-Al 2 Cu, despite its high volume fraction of ~10%, does not provide load transfer strengthening during creep deformation. Instead, the lattice strain evolution suggests a new mechanism we term “load shuffling” wherein the initial load is transferred away from precipitate-free zones along the grain boundaries where most of the θ-Al 2 Cu particles are located to precipitate-strengthened grain interiors. Notwithstanding the lack of load transfer strengthening, the as-fabricated AM Al-Cu-Mn-Zr alloy still possesses improved creep resistance at 300 °C relative to a cast alloy with similar composition. The proposed load shuffling mechanism explains the lack of observed L1 2 -Al 3 Zr strengthening at 300 °C and helps identify several strategies for improvement of elevated-temperature mechanical response of AM Al alloys.

36 MATERIALS SCIENCE↗

Evolution of global and local deformation in additively manufactured octet truss lattice structures

Additively manufactured lattice truss structures, often referred to as architected cellular materials, present significant advantages over conventional structures due to their unique characteristics such as high strength-to-weight ratios and surface area-to-volume ratios. These geometrically complex structures, however, come with concomitant challenges for qualification and inspection. In this study, compression testing interrupted with micro-computed tomography inspection was conducted to monitor the evolution of global and local deformation throughout the loading process of 304L stainless steel octet truss lattice structures. Both two- and three-dimensional image analysis techniques were leveraged to characterize geometric heterogeneities resulting from the laser powder bed fusion manufacturing process as well as track the structure throughout deformation. Variations from model-predicted behavior resulting from these heterogeneities are considered relative to the predicted and actual responses of the structures during compression to better understand, model, and predict the octet truss lattice structure compression response.

36 MATERIALS SCIENCE↗

Creep deformation and cavitation in an additively manufactured Al-8.6Cu-0.4Mn-0.9Zr (wt%) alloy

Creep deformation and cavitation were investigated at 300 ºC in both tension and compression for an additively manufactured Al-8.6Cu-0.5Mn-0.9Zr (wt%) alloy in the as-fabricated state and after various aging treatments (aging at 300 °C/200 h or 350 °C/24 h and overaging at 400 °C/200 h). Creep mechanisms at 300 °C were determined by relating the measured creep response to corresponding microstructural and X-ray computed tomography observations. In compression, alloys in the as-fabricated and two aging conditions exhibited similarly high creep resistance. Overaging (400 °C/200 h) led to substantial coarsening of intragranular θ-Al2Cu precipitates and an expected drop in their Orowan strengthening contribution. In tension, minimum strain rates comparable to those in compression were obtained at any given stress; however, upon accumulation of some plastic strain in the matrix, creep cavities started to form, leading to accelerated tertiary stage creep deformation and rupture. Cavitation occurred exclusively along melt pool boundaries due to locally enhanced diffusion enabled by (i) large grain-boundary area in adjacent fine-grained zones and (ii) localization of creep strain in nearby heat-affected zones. Although cavity growth was initially diffusion-controlled, its rate was determined by matrix creep rate, consistent with constrained cavity growth mechanisms. This study reveals how microstructural complexities induced by the additive manufacturing process affect the creep and cavitation behavior of Al-Cu-Mn-Zr alloys. The underlying creep and cavitation mechanisms uncovered in this study point to pathways that improve the high-temperature properties of additively manufactured alloys.

36 MATERIALS SCIENCE↗

Thermal energy evolution and mechanical deformation of monocrystalline yttria-stabilized zirconia nanoparticles in aerosol deposition processes

Aerosol deposition (AD) is a coating process wherein aerosol particles are impacted on a target substrate. There are fundamental differences between the AD process (cold impact), where particle translational kinetic energy is high and thermal energy is low, and thermal spray deposition (thermal impact), where translational energy is lower but thermal energy is high. To better compare cold and thermal impact effects on particles, we carried out molecular dynamics simulations using yttria-stabilized zirconia (YSZ) nanoparticles on YSZ substrates as a model system. We performed cold impact simulations at 300 K with variable impact velocity in the 500 ms –1 –1500 ms –1 range to understand how increasing translational kinetic energy affects thermal energy and mechanical evolution. We then performed thermal impact simulations at variable temperature and impact velocity, but where the total kinetic energy of the nanoparticle was equivalent to that of a 300 K, 1000 impact. In cold impact, the temperature increases in YSZ nanoparticles at a rate of 10 13 – 10 14 K s –1 , and large temperature gradients result. Conversely, in thermal impact, nanoparticle temperatures remain uniform. Furthermore, the temperature gradients during cold impact coincide with plastic deformation in nanoparticles, while with larger thermal energies, plastic deformation is reduced.

42 ENGINEERING↗

Large-scale metal strip for power storage and energy conversion applications by machining-based deformation processing

Machining-based deformation processing is used to produce metal foil and flat wire (strip) with suitable properties and quality for electrical power and renewable energy applications. In contrast to conventional multistage rolling, the strip is produced in a single-step and with much less process energy. Examples are presented from metal systems of varied workability, and strip product scale in terms of size and production rate. By utilizing the large-strain deformation intrinsic to cutting, bulk strip with ultrafine-grained microstructure, and crystallographic shear-texture favourable for formability, are achieved. In conclusion, implications for production of commercial strip for electric motor applications and battery electrodes are discussed.

24 POWER TRANSMISSION AND DISTRIBUTION↗

A continuum framework for coupled solid deformation–fluid flow through anisotropic elastoplastic porous media

We present a continuum framework for coupled solid deformation–fluid flow in anisotropic elastoplastic porous media. A thermodynamic formulation of the coupled processes gives rise to an anisotropic Biot tensor that is a function of drained elastic tangent moduli tensor of the solid skeleton and the intrinsic bulk modulus of the solid constituent. Two effective stress measures emerge from the formulation, namely, σ', which is energy-conjugate to the elastic strain, and σ'', which is energy-conjugate to the plastic strain. For the special case of transverse isotropy that is commonly encountered in natural rocks, the Biot tensor can be expressed in terms of its normal and tangential components to the bedding plane, along with a microstructure tensor. Apart from its thermodynamic consistency, an advantage of this new formulation is that standard mixed finite element formulation can be employed to discretize the domain and solve initial boundary-value problems. We conduct plane strain simulations of coupled solid deformation–fluid flow in a transversely isotropic porous medium to demonstrate the impacts of material anisotropy, stress history, and the Biot tensor on the system response.

42 ENGINEERING↗

A cohesive zone treatment for the material point method involving problems of large deformation and damage

A new algorithm is described that permits the use of cohesive zones in the material point method for problems involving large deformation and fracture. In contrast to previous cohesive zone implementations, this method does not utilize massless surface-element particles. Instead, cohesive tractions are computed using the shape function mappings from a reference grid configuration in combination with explicitly defined particle surface normals and surface positions. These normals and relative surface positions are updated each time step according to particle deformation. The tractions are converted to cohesive forces using the nodal areas and mapped back to particles using the same reference shape function mappings. These forces are then remapped by conventional particle-to-grid interpolation as external forces using the current-configuration shape-function mappings. This allows highly compliant cohesive zones to function over jump displacements larger than a grid cell. Upon damage, these interfaces can revert to conventional multi-field contact surfaces. This approach is general and readily applies to two and three dimensions as well as being compatible with damage-field gradient partitioning offering exceptional computational flexibility. The framework for this method enables other capabilities, such as improved contact precision using explicitly defined surface normals and positions, and a method to mitigate spurious material damage at weak discontinuities between stiff brittle materials and soft or compliant materials.

Cohesive zone↗

Effect of strain rate on the deformation of hollow CoS nanoboxes and doubly porous self-assembled films

Nanomaterials with multiscale porosity are attractive as lightweight structural materials because unique deformation mechanisms can be programmed at different length scales. Here, we explore this concept by investigating the mechanics of hollow nanoboxes, as well as films self-assembled from nanoboxes. Hollow CoS nanoboxes with lengths of 900 nm and <30 nm wall thickness are synthesized using colloidal methods. Individual nanoboxes are compressed inside a scanning electron microscope at strain rates of 0.001 s –1 , 0.01 s –1 , and 0.1 s –1 . Nanoboxes are found to have a first peak stress of 15 MPa and loading modulus of ~240 MPa regardless of strain rate. The nanoboxes deform through ductile, plastic bending of side walls at 0.001 s –1 strain rate, while brittle fracture occurs at the higher strain rates. Self-assembly of these nanoboxes results in films with relative density of <0.1. Nanoindentation shows strain rate independent behavior with average modulus and hardness of ~15 MPa and ~230 kPa, respectively. Furthermore, the mechanical behavior of the film is compared to that of the nanobox building blocks, cellular foams and granular materials.

36 MATERIALS SCIENCE↗

The deformation and burst behavior of Zircaloy-4 cladding tubes with hydride rim features subject to internal pressure loads

This study is motivated by the desire to conduct a separate effects test replicating specific aspects of an in-pile pulse reactor test on high exposure light water reactor (LWR) fuel rods. The principal purpose of the tests was to determine whether temperature and or hydrogen concentration thresholds exist in assessing the vulnerability of a stress relieved zirconium alloy cladding tubes to low strain ruptures. A secondary objective was to determine whether observations of the cladding stress during deformation could aid in the understanding of the crack formation and propagation in cladding tubes with hydride rim features. Here, the study utilized artificially hydrided Zircaloy-4 cladding tubes and an isothermal, internal pressure test that was controlled with an in-situ strain measurement. The test results show a clear transition in failure vulnerability between room temperature and 150 °C. Below 150 °C, cladding tubes rupture at very low uniform plastic strain—even at relatively modest cladding hydrogen levels. At and above 150 °C, cladding tubes only rupture at low uniform plastic strain if the cladding hydrogen content is greater than 500 ppm and usually experience at least some modest amount of plastic deformation prior to rupture. Post-test metallographs from non-ruptured cladding tubes show numerous primary cracks forming in the hydride rim and arresting at the metal/hydride interface. This observation combined with the decrease in bulk yielding of hydrided cladding tubes when compared to fresh non-hydrided tubes leads to the conclusion that the fracture stress of the hydride rims is related to and bounded by the yield stress of the zirconium metal. Some evidence is presented for a change in crack propagation mechanism from one of void formation on hydride plates and linkage at temperatures below 150 °C to more classical ductile shearing beneath the primary crack tip at temperatures above 150 °C. This apparent change in crack propagation mechanism may help explain the observed temperature and hydrogen concentration thresholds.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Soft interface instability and gas flow channeling in low-permeability deformable media

Understanding gas percolation through a clay layer or a shale formation is of great importance for the development of a geologic repository for nuclear waste disposal, a subsurface system for gas storage, and an engineering approach for hydrocarbon extraction from unconventional reservoirs. Gas injection experiments have revealed complex dynamic behaviours of gas percolation through water saturated compacted bentonite, characterized by a high breakthrough pressure, rapid breakthrough, a pressure/stress decay after the breakthrough, a relatively high migration rate, high-frequency periodic/nonperiodic variations in flow rate, stepwise rate reductions during relaxation, and low gas saturation over the whole process, all indicating channelling nature of the processes. Using linear stability analyses, we show that this channelling can autonomously emerge from the instability of the deformable interface between the injected gas and the compacted bentonite matrix driven by local stress concentration, pore dilation, and hydrologic gradient. Channel patterns formed would possess a fractal geometry. We further show that, once a percolating channel is established, the gas injected would percolate through the channel in a chain of gas bubbles, also due to the interface instability, resulting in periodic/chaotic variations in gas flow rate. Our work provides a unified explanation for key features observed for gas percolation in low-permeability deformable media. The work also suggests a possibility of designing an engineered barrier system for a nuclear waste repository that can have controllable gas release while limit water transport.

Bentonite↗

A study of adhesive bonding in metal–metal, metal–CFRP, and CFRP–CFRP material combinations under shear deformation: Fracture morphologies and damage mechanisms

Safe design of adhesive joining in multi-materials in engineered structures requires the accumulation of numerous experimental data on the failure behavior of various adhesively-bonded material combinations under different loading conditions. The deep understanding of mechanical performance, fracturing morphologies, and main damage mechanisms is also quintessential for accelerating the development of proper physics-based and multi-scale models for assisting the design. Towards this goal, this work presents a comprehensive characterization of the failure behavior of adhesively-bonded metal–metal, metal–CFRP, and CFRP–CFRP material combinations under global shear deformation via single lap shear testing. Thanks to a synergistic combination of measurement methods by using Digital Imaging Correlation (DIC) and 3D optical profilometry, adhesive features on the adherend after failure were quantified and the main progressive damage mechanisms were identified. The characterization performed in this work provides quantitative data that contributes to a better understanding of shear failure in adhesive bonding across different bi-material combinations. Finally, the obtained results have practical implications, including the potential to enhance adhesive bonding design, identify failure causes in adhesive joints, and develop or validate computational models capable of capturing the observed behavior in various adhesively-bonded materials under global shear deformation.

36 MATERIALS SCIENCE↗

Tensile and compressive plastic deformation behavior of medium-entropy Cr-Co-Ni single crystals from cryogenic to elevated temperatures

The equiatomic Cr-Co-Ni medium-entropy alloy has the face-centered cubic (FCC) structure. Bulk single crystals of this alloy were grown and tested in tension and compression between 14 K and 1373 K with the loading axis parallel to [23]. At room temperature, the critical resolved shear stress (CRSS) for {111}<10> slip is 65 ± 5 MPa and does not exhibit a tension-compression asymmetry. It does, however, increase significantly as the test temperature decreases. A dulling of this temperature dependence occurs below 50 K, which may be due to the inertia effect. When the measured values above 50 K are extrapolated to lower temperatures, a value of 225 MPa is estimated for the CRSS at 0 K. This is larger than that (168 MPa) previously determined for the equiatomic Cr-Mn-Fe-Co-Ni high-entropy alloy using a similar procedure. The stacking fault energy of the present Cr-Co-Ni is estimated to be about 14 mJm-2, which is sufficiently low to account for deformation twinning both at 77 K and room temperature. Twinning at 77 K occurs on conjugate (1) planes at an onset shear stress of 482 MPa after primary slip and propagates in the form of Lüders deformation. At room temperature, twinning occurs uniformly throughout the gauge section on primary (111) planes at an onset shear stress of 381 MPa after primary and subsequent conjugate slip. Thin layers with the hexagonal close-packed stacking are observed in association with twinning both at 77 K and room temperature.

36 MATERIALS SCIENCE↗

Deformation, dislocation evolution and the non-Schmid effect in body-centered-cubic single- and polycrystal tantalum

A physically-informed continuum crystal plasticity model is presented to elucidate deformation mechanisms, dislocation evolution and the non-Schmid effect in body-centered-cubic (bcc) tantalum widely used as a key structural material for mechanical and thermal extremes. We show the unified structural modeling framework informed by mesoscopic dislocation dynamics simulations is capable of capturing salient features of the large inelastic behavior of tantalum at quasi-static (10 -3 s -1 ) to extreme strain rates (5000 s -1 ) and at low (77 K) to high temperatures (873 K) at both single- and polycrystal levels. Here we also present predictive capabilities of the model for microstructural evolution in the material. To this end, we investigate the effects of dislocation interactions on slip activities, instability and the non-Schmid behavior at the single crystal level. Furthermore, ex situ measurements on crystallographic texture evolution and dislocation density growth are carried out for polycrystal tantalum specimens at increasing strains. Numerical simulation results also support that the modeling framework is capable of capturing the main features of the polycrystal behavior over a wide range of strains, strain rates and temperatures. The theoretical, experimental and numerical results at both single- and polycrystal levels provide critical insight into the underlying physical pictures for micro- and macroscopic responses and their relations in this important class of refractory bcc materials undergoing large inelastic deformations.

36 MATERIALS SCIENCE↗