Effects of Annealing Process on the Formability of Friction Stir Welded Al-Li Alloy 2195 Plates

NASA Technical Reports Server (NTRS)

Chen, Po-Shou; Bradford, Vann; Russell, Carolyn

2011-01-01

Large rocket cryogenic tank domes have typically been fabricated using Al-Cu based alloys like Al-Cu alloy 2219. The use of aluminum-lithium based alloys for rocket fuel tank domes can reduce weight because aluminum-lithium alloys have lower density and higher strength than Al-Cu alloy 2219. However, Al-Li alloys have rarely been used to fabricate rocket fuel tank domes because of the inherent low formability characteristic that make them susceptible to cracking during the forming operations. The ability to form metal by stretch forming or spin forming without excessive thinning or necking depends on the strain hardening exponent "n". The stain hardening exponent is a measure of how rapidly a metal becomes stronger and harder. A high strain hardening exponent is beneficial to a material's ability to uniformly distribute the imposed strain. Marshall Space Flight Center has developed a novel annealing process that can achieve a work hardening exponent on the order of 0.27 to 0.29, which is approximately 50% higher than what is typically obtained for Al-Li alloys using the conventional method. The strain hardening exponent of the Al-Li alloy plates or blanks heat treated using the conventional method is typically on the order of 0.17 to 0.19. The effects of this novel annealing process on the formability of friction stir welded Al-Li alloy blanks are being studied at Marshall Space Flight Center. The formability ratings will be generated using the strain hardening exponent, strain rate sensitivity and forming range. The effects of forming temperature on the formability will also be studied. The objective of this work is to study the deformation behavior of the friction stir welded Al-Li alloy 2195 blank and determine the formability enhancement by the new annealing process.

Effect of the nature of grain boundary regions on cavitation of a superplastically deformed aluminium alloy

DOE Office of Scientific and Technical Information (OSTI.GOV)

Blandin, J.J.; Varloteaux, A.; Suery, M.

Superplastic deformation of aluminium alloys induces cavity formation throughout the material, so that superplastic forming usually requires to be carried out under superimposed gas pressure to minimize strain-induced damage. This paper deals with the beneficial effects of heat treatment at high temperature for several hours before deformation on cavitation behavior of a superplastically deformed 7475 alloy. Transmission electron microscopy observations show that several microstructural transformations are induced by superplastic deformation and affected by the heat treatment. At first, the generation of dispersoid free zones at the periphery of the grains is observed, the composition of which depends on the priormore » history of the specimen. Secondly, the formation of long thin fibers extending in the cavities in the as received specimens, these fibers being no longer present in the heat-treated conditions. A TEM characterization of the fibers is presented and a mechanism of their formation is discussed. Such a reduction of the cavitation level for a given strain is interesting in view of superplastic forming of aluminium alloys under atmospheric pressure.« less

Effect of thermal processing practices on the properties of superplastic Al-Li alloys

NASA Technical Reports Server (NTRS)

Hales, Stephen J.; Lippard, Henry E.

1993-01-01

The effect of thermal processing on the mechanical properties of superplastically formed structural components fabricated from three aluminum-lithium alloys was evaluated. The starting materials consisted of 8090, 2090, and X2095 (Weldalite(TM) 049), in the form of commercial-grade superplastic sheet. The experimental test matrix was designed to assess the impact on mechanical properties of eliminating solution heat treatment and/or cold water quenching from post-forming thermal processing. The extensive hardness and tensile property data compiled are presented as a function of aging temperature, superplastic strain and temper/quench rate for each alloy. The tensile properties of the materials following superplastic forming in two T5-type tempers are compared with the baseline T6 temper. The implications for simplifying thermal processing without degradation in properties are discussed on the basis of the results.

Mechanistic Studies of Superplasticity of Structural Ceramics

DTIC Science & Technology

1992-02-01

green compact, with a higher density and and most of Ine heavier transition-metal fewer defects and agglomerates, has a cations of the third row, is very...between 60% to 65% of the theoretical defects is merely one which mediates the above solid "elec- density. Samples of 2Y-TZP and other TZPs were prepared...trolyte," although any tendency toward binding between similarly, except for a smaller dopant concentration ot 0.6% point defects and dopants to form

Effects of plastic deformation on microstructure and superplasticity of the in situ Al3Ti/2024Al composites

NASA Astrophysics Data System (ADS)

Jiao, Lei; Yang, Yonggang; Li, Hui; Zhao, Yutao; Wang, Xiaolu

2018-05-01

In this study, the in situ Al3Ti/2024Al composites were successfully fabricated by direct melt reaction method and subjected to forging and friction stir processing (FSP) to achieve superplasticity. Then, the microstructure and superplastic tensile behavior of the composites were investigated. The results show that the reinforcement particles are broken and grains are fine after plastic processing. Particularly, the size of reinforcement particles ranges from 0.2 μm to 5 μm and the average size of fine equiaxed grains is 5 μm after FSP processing. And the superplasticity of the composites was improved apparently. The maximum elongation of 642% was obtained at 0.15 s‑1 and 510 °C for the FSP specimen, with a strain rate sensitive parameter (m) of 0.58, indicating the FSP specimen has obtained excellent high strain rate superplasticity. The strain rate sensitivity parameter, m, ranges from 0.23 to 0.58, and the activation energy was calculated to be 135.24 kJ mol‑1. All results indicated that the main superplastic deformation mechanism was grain boundary sliding (GBS) for the FSP Al3Ti/2024Al composites.

Superplastic forming of Al-Li alloys for lightweight, low-cost structures

NASA Technical Reports Server (NTRS)

Hales, Stephen J.; Wagner, John A.

1991-01-01

Superplastic forming of advanced aluminum alloys is being evaluated as an approach for fabricating low-cost, light-weight, cryogenic propellant tanks. Built-up structure concepts (with inherent reduced scrap rate) are under investigation to offset the additional raw material expenses incurred by using aluminum lithium alloys. This approach to fabrication offers the potential for significant improvements in both structural efficiency and overall manufacturing costs. Superplasticity is the ability of specially processed material to sustain very large forming strains without failure at elevated temperatures under controlled deformation conditions. It was demonstrated that superplastic forming technology can be used to fabricate complex structural components in a single operation and increase structural efficiency by as much as 60 percent compared to conventional configurations in skin-stiffened structures. Details involved in the application of this technology to commercial grade superplastic aluminum lithium material are presented. Included are identification of optimum forming parameters, development of forming procedures, and assessment of final part quality in terms of cavitation volume and thickness variation.

High-strain-rate superplasticity of the Al-Zn-Mg-Cu alloys with Fe and Ni additions

NASA Astrophysics Data System (ADS)

Kotov, A. D.; Mikhaylovskaya, A. V.; Borisov, A. A.; Yakovtseva, O. A.; Portnoy, V. K.

2017-09-01

During high-strain-rate superplastic deformation, superplasticity indices, and the microstructure of two Al-Zn-Mg-Cu-Zr alloys with additions of nickel and iron, which contain equal volume fractions of eutectic particles of Al3Ni or Al9FeNi, have been compared. It has been shown that the alloys exhibit superplasticity with 300-800% elongations at the strain rates of 1 × 10-2-1 × 10-1 s-1. The differences in the kinetics of alloy recrystallization in the course of heating and deformation at different temperatures and rates of the superplastic deformation, which are related to the various parameters of the particles of the eutectic phases, have been found. At strain rates higher than 4 × 10-2, in the alloy with Fe and Ni, a partially nonrecrystallized structure is retained up to material failure and, in the alloy with Ni, a completely recrystallized structure is formed at rates of up to 1 × 10-1 s-1.

Constitutive Equation with Varying Parameters for Superplastic Flow Behavior

NASA Astrophysics Data System (ADS)

Guan, Zhiping; Ren, Mingwen; Jia, Hongjie; Zhao, Po; Ma, Pinkui

2014-03-01

In this study, constitutive equations for superplastic materials with an extra large elongation were investigated through mechanical analysis. From the view of phenomenology, firstly, some traditional empirical constitutive relations were standardized by restricting some strain paths and parameter conditions, and the coefficients in these relations were strictly given new mechanical definitions. Subsequently, a new, general constitutive equation with varying parameters was theoretically deduced based on the general mechanical equation of state. The superplastic tension test data of Zn-5%Al alloy at 340 °C under strain rates, velocities, and loads were employed for building a new constitutive equation and examining its validity. Analysis results indicated that the constitutive equation with varying parameters could characterize superplastic flow behavior in practical superplastic forming with high prediction accuracy and without any restriction of strain path or deformation condition, showing good industrial or scientific interest. On the contrary, those empirical equations have low prediction capabilities due to constant parameters and poor applicability because of the limit of special strain path or parameter conditions based on strict phenomenology.

International Conference on Superplasticity and Superplastic Forming

DTIC Science & Technology

1988-08-09

aluminides and other intermetallic compounds, as well as certain metal matrix composites. The applications of SPF parts continues to increase both in...aerospace and non-aerospace areas. Titanium continues to be the primary material processed for aerospace, although the development in Al SPF is accelerating...Electrical Technology of SCMI Superplastic Forming of Ti-Alloy Turbine Blade Paper 28 WANG CHENG and LUO YING-SHE, Xiangtan University Nc~’ Advance

Finite Element Simulations for Investigating the Effects of Specimen Geometry in Superplastic Tensile Tests

NASA Astrophysics Data System (ADS)

Nazzal, Mohammad; Abu-Farha, Fadi; Curtis, Richard

2011-08-01

Characterizing the behavior of superplastic materials is largely based on the uniaxial tensile test; yet the unique nature of these materials requires a particularly tailored testing methodology, different to that used with conventional materials. One of the crucial testing facets is the specimen geometry, which has a great impact on the outcome of a superplastic tensile test, as a result of the associated extreme conditions. And while researchers agree that it should take a notably different form than the typical dog-bone shape; there is no universal agreement on the specimen's particular size and dimensions, as evident by the disparities in test specimens used in the various superplastic testing efforts found throughout the literature. In view of that, this article is dedicated to understanding the effects of specimen geometry on the superplastic behavior of the material during tensile testing. Deformation of the Ti6Al4V titanium alloy is FE simulated based on a multitude of specimen geometries, covering a wide range of gauge length, gauge width, grip length, and grip width values. The study provides key insights on the influences of each geometrical parameter as well as their interactions, and provides recommendations on selecting the specimen's proportions for accurate and unified tensile testing of superplastic materials.

Superplastic forging nitride ceramics

DOEpatents

Panda, P.C.; Seydel, E.R.; Raj, R.

1988-03-22

A process is disclosed for preparing silicon nitride ceramic parts which are relatively flaw free and which need little or no machining, said process comprising the steps of: (a) preparing a starting powder by wet or dry mixing ingredients comprising by weight from about 70% to about 99% silicon nitride, from about 1% to about 30% of liquid phase forming additive and from 1% to about 7% free silicon; (b) cold pressing to obtain a preform of green density ranging from about 30% to about 75% of theoretical density; (c) sintering at atmospheric pressure in a nitrogen atmosphere at a temperature ranging from about 1,400 C to about 2,200 C to obtain a density which ranges from about 50% to about 100% of theoretical density and which is higher than said preform green density, and (d) press forging workpiece resulting from step (c) by isothermally uniaxially pressing said workpiece in an open die without initial contact between said workpiece and die wall perpendicular to the direction of pressing and so that pressed workpiece does not contact die wall perpendicular to the direction of pressing, to substantially final shape in a nitrogen atmosphere utilizing a temperature within the range of from about 1,400 C to essentially 1,750 C and strain rate within the range of about 10[sup [minus]7] to about 10[sup [minus]1] seconds[sup [minus]1], the temperature and strain rate being such that surface cracks do not occur, said pressing being carried out to obtain a shear deformation greater than 30% whereby superplastic forging is effected.

Investigation by Differential Scanning Calorimetry of Microstructure in a Superplastic Al-Mg-Zr Alloy.

DTIC Science & Technology

1987-06-01

cold-rolled zinc-copper-aluminum eutectic alloy exhibited this superplastic response. Superplasticity was initially viewed as a curious observation...limited to eutectic alloys when tested under the correct laboratory conditions. However, in 1962 Underwood [Ref. 23 reviewed Soviet work; this review...formation of a very fine dispersoid, ZrAI3. This dispersoid results in grain refinement, raises the recrystallization temperature (Ref. 7:p. 414] and gives

Phase state of a Bi-43 wt % Sn superplastic alloy and its changes under the effect of external mechanical stresses and aging

NASA Astrophysics Data System (ADS)

Korshak, V. F.; Chushkina, R. A.; Shapovalov, Yu. A.; Mateichenko, P. V.

2011-07-01

Samples of a Bi-43 wt % Sn superplastic alloy have been studied by X-ray diffraction in the ascast state, after compression of as-cast samples to ˜70% on a hydraulic press, after aging in the as-cast and preliminarily compressed state, and using samples deformed under superplastic conditions. The X-ray diffraction studies have been carried out using a DRON-2.0 diffractometer in Cu Kα radiation. The samples aged and deformed under superplasticity conditions have been studied using electron-microprobe analysis in a JSM-820 scanning electron microscope equipped with a LINK AN/85S EDX system. It has been found that the initial structural-phase state of the alloy was amorphous-crystalline. Causes that lead to a change in this state upon deformation and aging are discussed. A conclusion is made that the superplasticity effect manifests itself against the background of processes that are stipulated by the tendency of the initially metastable alloy to phase equilibrium similarly to what is observed in the Sn-38 wt % Pb eutectic alloy studied earlier.

Recrystallization and superplasticity at 300 C in an aluminum-magnesium alloy

NASA Technical Reports Server (NTRS)

Hales, S. J.; Mcnelley, T. R.; Mcqueen, H. J.

1991-01-01

Variations in thermomechanical processing (TMP) which regulate the microstructural characteristics and superplastic response of an Al-10Mg-0.1Zr alloy at 300 C were evaluated. Mechanical property data revealed that the superplastic ductility can be enhanced by simultaneously increasing the total rolling strain, the reduction per pass, and the duration of reheating intervals between passes during isothermal rolling. Texture and microscopy data were consistent with the development of a refined microstructure by recovery-dominated processes, i.e., continuous recrystallization, during the processing. The mechanisms by which a refined substructure can be progressively converted into a fine-grained structure during repeated cycles of deformation and annealing are addressed. A qualitative description of the complex sequence of developments leading to a microstructure better suited to support superplastic response is presented.

Test of superplastically formed corrugated aluminum compression specimens with beaded webs

NASA Technical Reports Server (NTRS)

Davis, Randall C.; Royster, Dick M.; Bales, Thomas T.; James, William F.; Shinn, Joseph M., Jr.

1991-01-01

Corrugated wall sections provide a highly efficient structure for carrying compressive loads in aircraft and spacecraft fuselages. The superplastic forming (SPF) process offers a means to produce complex shells and panels with corrugated wall shapes. A study was made to investigate the feasibility of superplastically forming 7475-T6 aluminum sheet into a corrugated wall configuration and to demonstrate the structural integrity of the construction by testing. The corrugated configuration selected has beaded web segments separating curved-cap segments. Eight test specimens were fabricated. Two specimens were simply a single sheet of aluminum superplastically formed to a beaded-web, curved-cap corrugation configuration. Six specimens were single-sheet corrugations modified by adhesive bonding additional sheet material to selectively reinforce the curved-cap portion of the corrugation. The specimens were tested to failure by crippling in end compression at room temperature.

Superplastic forming of ceramic insulation

NASA Technical Reports Server (NTRS)

Nieh, T. G.; Wittenauer, J. P.; Wadsworth, J.

1992-01-01

Superplasticity has been demonstrated in many fine-grained structural ceramics and ceramic composites, including yttria-stabilized tetragonal zirconia polycrystal (YTZP), alumina, and Al2O3-reinforced zirconia (Al2O3/YTZ) duplex composites and SiC-reinforced Si3N4. These superplastic ceramics obviously offer the potential benefit of forming net shape or near net shape parts. This could be particularly useful for forming complicated shapes that are difficult to achieve using conventional forming techniques, or require elaborate, subsequent machining. In the present study, we successfully demonstrated the following: (1) superplastic 3Y-TXP and 20 percent Al2O3/YTZ composite have for the first time been successfully deformed into hemispherical caps via a biaxial gas-pressure forming technique; (2) no experimental difficulty was encountered in applying the required gas pressures and temperatures to achieve the results, thus, it is certain that higher rates of deformation than those presented in this study will be possible by using the current test apparatus at higher temperatures and pressures; and (3) an analytical model incorporating material parameters, such as variations during forming in the strain rate sensitivity exponent and grain growth-induced strain hardening, is needed to model accurately and therefore precisely control the biaxial gas-pressure forming of superplastic ceramics. Based on the results of this study, we propose to fabricate zirconia insulation tubes by superplastic extrusion of zirconia polycrystal. This would not only reduce the cost, but also improve the reliability of the tube products.

Superplastic Forming/Adhesive Bonding of Aluminum (SPF/AB) Multi-Sheet Structures

NASA Technical Reports Server (NTRS)

Wagner, John A. (Technical Monitor); Will, Jeff D.; Cotton, James D.

2003-01-01

A significant fraction of airframe structure consists of stiffened panels that are costly and difficult to fabricate. This program explored a potentially lower-cost processing route for producing such panels. The alternative process sought to apply concurrent superplastic forming and adhesive bonding of aluminum alloy sheets. Processing conditions were chosen to balance adequate superplasticity of the alloy with thermal stability of the adhesive. As a first objective, an air-quenchable, superplastic aluminum-lithium alloy and a low-volatile content, low-viscosity adhesive with compatible forming/curing cycles were identified. A four-sheet forming pack was assembled which consisted of a welded two-sheet core separated from the face sheets by a layer of adhesive. Despite some preliminary success, of over 30 forming trials none was completely successful. The main problem was inadequate superplasticity in the heat-affected zones of the rib welds, which generally fractured prior to completion of the forming cycle. The welds are a necessary component in producing internal ribs by the 'four-sheet' process. Other challenges, such as surface preparation and adhesive bonding, were adequately solved. But without the larger issue of tearing at the weld locations, complex panel fabrication by SPF/AB does not appear viable.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kral, Petr, E-mail: pkral@ipm.cz; CEITEC – IPM ASCR, v.v.i., Zizkova 22, CZ-61662 Brno; Dvorak, Jiri

The deformation kinetics of ultrafine-grained Ti-6Al-4V with mean (sub)grain size about 150 nm (produced by isothermal multiaxial forging) and superplastic properties at the relatively low temperature of 873 K was investigated in compression and tension over a large range of strain rates from 10{sup −7} to 10{sup −2} s{sup −1}. Electron microscopic observations showed that the grains coarsen during deformation towards the quasi-stationary spacing w{sub qs} of strain induced boundaries. In spite of the grain coarsening the grains were generally smaller than w{sub qs} allowing high-angle boundaries to dominate the quasi-stationary strength. Texture measurements indicate that dislocation glide plays amore » large role in deformation. Glide in this alloy is significantly influenced by solid solution strengthening leading to a stress sensitivity of strain rate of n = 3. The present ultrafine-grained Ti alloy displays a stress sensitivity exponent n = 2 over an extended stress range where its superplastic behavior is optimal. While the deformation kinetics of present ultrafine-grained Ti alloy can be roughly explained by the traditional formula for superplastic flow, the significant discrepancy to the measured values suggests that solid solution strengthening must be taken into account to get a complete insight. - Highlights: • The UFG Ti-6Al-4V alloy behaves superplastically at low temperature of 873 K. • Grain coarsening at low stresses limits superplasticity of UFG Ti alloy. • Solute strengthening plays an important role in low-temperature superplasticity. • Acceleration of creep in UFG Ti alloy is caused by processes related to hab.« less

Superplastic flow lubricates carbonate faults during earthquake slip

NASA Astrophysics Data System (ADS)

De Paola, Nicola; Holdsworth, Robert; Viti, Cecilia; Collettini, Cristiano; Faoro, Igor; Bullock, Rachael

2014-05-01

Tectonic earthquakes are hosted in the shallower portion of crustal fault zones, where fracturing and cataclasis are thought to be the dominant processes during frictional sliding. Aseismic shear in lower crust and lithospheric mantle shear zones is accomplished by crystal plasticity, including superplastic flow acting at low strain rates on ultrafine-grained rocks. Superplasticity has also been observed at high strain rates for a range of nano-phase alloys and ceramics, and could potentially occur in fine-grained geological materials, if deformed at high strain rates and temperatures. We performed a set of displacement-controlled experiments to explore whether superplastic flow can effectively weaken faults, and facilitate earthquake propagation. The experiments were performed on fine-grained synthetic gouges (63 < f < 93 μm) of undeformed, protolith carbonate rocks using a rotary shear apparatus, at target speed v = 1 ms-1, normal stresses σn = 12-18 MPa, displacements d from 0.009 to 1.46 m, room temperature and humidity conditions. Samples were recovered after each experiment to study the slip zone microstructures. The integration of experimental data and microstructural observations shows that during sliding at seismic velocity, brittle fracturing and cataclasis control shear localization and grain size reduction in the slip zone at relatively low temperatures (T ≤ 100 °C). Stress levels predicted by such behaviours match those measured during the experiments. As temperatures rise due to frictional heating (T ≥ 500 °C), dislocation creep mechanisms start to accommodate intragranular strain, and play a key role in producing nanoscale subgrains (< 200 nm) in the slip zone. At this stage, despite of the presence of nanoparticles in the slip zone and the attainment of seismic slip rates, the measured frictional strength of experimental faults still lies within Byerlee's range of values μ = 0.8. This suggests that the slip zone bulk strength at this stage is controlled by cataclastic frictional sliding rather than by dislocation creep or nanopowder lubrication mechanisms. When T ≥ 800 °C are attained, micro-textures diagnostic of diffusion-dominated grain boundary sliding are widespread within the slip zone, and suggest bulk superplastic flow. Flow stresses predicted by superplasticity constitutive laws at the slip zone temperatures, grain sizes and strain rates attained during the experiments match those we measured in the laboratory (μ = 0.16). We propose therefore that the activation of diffusion creep at high temperatures (T ≥ 800 °C) leads to slip zone-localised superplastic flow and that this causes the dynamic weakening of carbonate faults at seismic slip rates. Note, however, that both cataclasis and dislocation creep operating at lower temperatures, during the earlier stages of slip, are critical, precursory processes needed to produce the nanoscale grain sizes required to activate grainsize sensitive mechanisms during superplastic flow. Finally, the re-strengthening observed during the decelerating phase of deformation can be explained by the falling temperature "switching off" slip zone-localized superplasticity, leading to a return to frictional sliding. These results indicate that superplastic flow can effectively weaken faults, and facilitate earthquake propagation in the upper crust.

Superplastic Forming 40 Years and Still Growing

NASA Astrophysics Data System (ADS)

Barnes, A. J.

2007-08-01

In late 1964 Backofen, Turner & Avery, at MIT, published a paper in which they described the “extraordinary formability” exhibited when fine-grain zinc-aluminum eutectoid (Zn 22 Al) was subjected to bulge testing under appropriate conditions. They concluded their research findings with the following insightful comment “ even more appealing is the thought of applying to superplastic metals forming techniques borrowed from polymer and glass processing.” Since then their insightful thought has become a substantial reality with thousands of tons of metallic sheet materials now being superplastically formed each year. This paper reviews the significant advances that have taken place over the past 40 years including alloy developments, improved forming techniques and equipment, and an ever increasing number of commercial applications. Current and likely future trends are discussed including; applications in the aerospace and automotive markets, faster-forming techniques to improve productivity, the increasing importance of computer modeling and simulation in tool design and process optimization and new alloy developments including superplastic magnesium alloys.

Continuous recrystallization during thermomechanical processing of a superplastic Al-10Mg-0.1Zr alloy

NASA Technical Reports Server (NTRS)

Hales, S. J.; Mcnelley, T. R.; Crooks, R.

1990-01-01

Microstructural evolution via static continuous recrystallization during thermomechanical processing of an Al-Mg-Zr alloy is addressed. Mechanical property data demonstrated that as-rolled material was capable of superplastic response without further treatment. Further, superplastic ductility at 300 C was enhanced by a factor of five by increasing the reheating time between rolling passes during processing also at 300 C. This enhanced ductility was associated with a Cu-texture and a microstructure consisting of predominantly high-angle boundaries. Processing to minimize recovery resulted in a strong Brass-texture component, a predominantly low-angle boundary microstructure and poorer ductility.

Joining of advanced materials by superplastic deformation

DOEpatents

Goretta, Kenneth C.; Routbort, Jules L.; Gutierrez-Mora, Felipe

2008-08-19

A method for utilizing superplastic deformation with or without a novel joint compound that leads to the joining of advanced ceramic materials, intermetallics, and cermets. A joint formed by this approach is as strong as or stronger than the materials joined. The method does not require elaborate surface preparation or application techniques.

Joining of advanced materials by superplastic deformation

DOEpatents

Goretta, Kenneth C.; Routbort, Jules L.; Gutierrez-Mora, Felipe

2005-12-13

A method for utilizing superplastic deformation with or without a novel joint compound that leads to the joining of advanced ceramic materials, intermetallics, and cermets. A joint formed by this approach is as strong as or stronger than the materials joined. The method does not require elaborate surface preparation or application techniques.

Strength enhancement process for prealloyed powder superalloys

NASA Technical Reports Server (NTRS)

Waters, W. J.; Freche, J. C.

1977-01-01

A technique involving superplastic processing and high pressure autoclaving was applied to a nickel base prealloyed powder alloy. Tensile strengths as high as 2865 MN/sq m at 480 C were obtained with as-superplastically deformed material. Appropriate treatments yielding materials with high temperature tensile and stress rupture strengths were also devised.

Deformation of superplastic alloys at relatively low strain rates

DOE Office of Scientific and Technical Information (OSTI.GOV)

Grivas, D.

1978-02-01

The superplastic and sub-superplastic creep properties of Pb-Sn eutectic and Al-Zn eutectoid alloys were studied. Various thermomechanical treatments we tested to check the possibilities of whether the subsuperplastic deformation mechanism is affected by these treatments. All thermomechanical histories were found to reveal the same stress exponent, which is believed to be indicative of the predominant mechanism. The mechanical data in the low stress region lead us to suggest that dislocation glide is the predominant mechanism in this region. At higher stresses extensive grain boundary sliding takes place and the dislocation movement is directed to relieve the stress concentration developed bymore » the grain movement.« less

Fabricating Structural Stiffeners By Superplastic Forming

NASA Technical Reports Server (NTRS)

Bales, Thomas T.; Shinn, Joseph M., Jr.; Hales, Stephen J.; James, William F.

1994-01-01

Superplastic forming (SPF) of aluminum alloys effective technique for making strong, lightweight structural components conforming to close dimensional tolerances. Technique applied in experimental fabrication of prototypes of stiffening ribs for cylindrical tanks. When making structural panel, stiffening ribs spot-welded to metal skin. Use of discrete eliminates machining waste, and use of SPF. Cost of fabrication reduced.

Formability of tufted 3-dimensional composite reinforcement

NASA Astrophysics Data System (ADS)

Liu, Ling Shan; Wang, Peng; Legrand, Xavier; Soulat, Damien

2016-10-01

In the aerospace industry, more and more complex preform for composite parts are needed. Traditionally, laminated reinforcement is largely used as the method. The development of tufting technology has now advanced to a stage whereby it can be employed to produce the 3D textile composite reinforcements. Because the tufting technology is user-friendly, in this study, the tufting parameters (tufting density, tufting length, tufting yarn orientations…) are varied, in order to improve the understanding of formability of the tufted 3D fabric during manufacturing, in particular the influence of the tufting yarns, the present work is performed to analyse the preforming behaviours of tufted 3D reinforcement in the hemispherical stamping process. The preforming behaviours are also compared with the ones of the multilayered forming. Interply sliding and winkling phenomenon during forming are fully influenced by tufting yarns on the material draw-in, by the orientations of tufting yarn, …

A Study on Infrared Local Heat Treatment for AA5083 to Improve Formability and Automotive Part Forming

NASA Astrophysics Data System (ADS)

Lee, Eun-Ho; Yang, Dong-Yol; Ko, SeJin

2017-10-01

Automotive industries are increasingly employing aluminum alloys for auto parts to reduce vehicle weight. However, the low formability of aluminum alloys has been an obstacle to their application. To resolve the formability problem, some studies involving heat treatments under laboratory conditions have been reported. However, for industrial applications, the heat treatment sequence, heating energy efficiency, and a commercial part test should be studied. This work shows an infrared (IR) local heat treatment, heating only small areas where the heat treatment is required, for an aluminum alloy to improve the formability with a reduction of heating energy. The experiment shows that the formability drastically increases when the aluminum alloy is heat treated between two forming stages, referred to as intermediate heat treatment. The microstructures of the test pieces are evaluated to identify the cause of the increase in the formability. For an industrial application, an aluminum tailgate, which cannot be manufactured without heat treatment, was successfully manufactured by the IR local heat treatment with a reduction of energy. A simulation was also conducted with a stress-based forming limit diagram, which is not affected by the strain path and heat treatment histories. The simulation gives a good prediction of the formability improvement.

Friction Stir Processing of As-Cast AA5083: Superplastic Response

DTIC Science & Technology

2009-06-01

3 A. ALUMINUM ALLOY 5083............................................................................3 B. SUPERPLASTICITY...ALUMINUM ALLOY 5083 The United States Navy is always considering the most effective and cost effective materials and manufacturing processes. These...desires have lead to a long-term interest in aluminum alloys for naval shipbuilding and design. The 5 -series aluminum alloys (Al-Mg system) are widely

Probing Formability Improvement of Ultra-thin Ferritic Stainless Steel Bipolar Plate of PEMFC in Non-conventional Forming Process

NASA Astrophysics Data System (ADS)

Bong, Hyuk Jong; Barlat, Frédéric; Lee, Myoung-Gyu

2016-08-01

Formability increase in non-conventional forming profiles programmed in the servo-press was investigated using finite element analysis. As an application, forming experiment on a 0.15-mm-thick ferritic stainless steel sheet for a bipolar plate, a primary component of a proton exchange membrane fuel cell, was conducted. Four different forming profiles were considered to investigate the effects of forming profiles on formability and shape accuracy. The four motions included conventional V motion, holding motion, W motion, and oscillating motion. Among the four motions, the holding motion, in which the slide was held for a certain period at the bottom dead point, led to the best formability. Finite element simulations were conducted to validate the experimental results and to probe the formability improvement in the non-conventional forming profiles. A creep model to address stress relaxation effect along with tool elastic recovery was implemented using a user-material subroutine, CREEP in ABAQUS finite element software. The stress relaxation and variable contact conditions during the holding and oscillating profiles were found to be the main mechanism of formability improvement.

Superplastic forging nitride ceramics

DOEpatents

Panda, Prakash C.; Seydel, Edgar R.; Raj, Rishi

1988-03-22

The invention relates to producing relatively flaw free silicon nitride ceramic shapes requiring little or no machining by superplastic forging This invention herein was made in part under Department of Energy Grant DE-AC01-84ER80167, creating certain rights in the United States Government. The invention was also made in part under New York State Science and Technology Grant SB1R 1985-10.

Fabrication and evaluation of superplastically formed/weld-brazed corrugated compression panels with beaded webs

NASA Technical Reports Server (NTRS)

Royster, D. M.; Davis, R. C.; Shinn, J. M., Jr.; Bales, T. T.; Wiant, H. R.

1985-01-01

A study was made to investigate the feasibility of superplastically forming corrugated panels with beaded webs and to demonstrate the structural integrity of these panels by testing. The test panels in the study consist of superplastically formed titanium alloy Ti-6Al-4V half-hat elements that are joined by weld-brazing to titanium alloy Ti-6Al-4V caps to form either single-corrugation compression panels or multiple-corrugation compression panels. Stretching and subsequent thinning of the titanium sheet during superplastic forming is reduced by approximately 35 percent with a shallow half-hat die concept instead of a deep die concept and results in a more uniform thickness across the beaded webs. The complete panels are tested in end compression at room temperature and the results compared with analysis. The heavily loaded panels failed at loads approaching the yield strength of the titanium material. At maximum load, the caps wrinkled locally accompanied with separation of the weld-braze joint in the wrinkle. None of the panels tested, however, failed catastrophically in the weld-braze joint. Experimental test results are in good agreement with structural analysis of the panels.

Method of producing superplastic alloys and superplastic alloys produced by the method

NASA Technical Reports Server (NTRS)

Troeger, Lillianne P. (Inventor); Starke, Jr., Edgar A. (Inventor); Crooks, Roy (Inventor)

2002-01-01

A method for producing new superplastic alloys by inducing in an alloy the formation of precipitates having a sufficient size and homogeneous distribution that a sufficiently refined grain structure to produce superplasticity is obtained after subsequent PSN processing. An age-hardenable alloy having at least one dispersoid phase is selected for processing. The alloy is solution heat-treated and cooled to form a supersaturated solid solution. The alloy is plastically deformed sufficiently to form a high-energy defect structure useful for the subsequent heterogeneous nucleation of precipitates. The alloy is then aged, preferably by a multi-stage low and high temperature process, and precipitates are formed at the defect sites. The alloy then is subjected to a PSN process comprising plastically deforming the alloy to provide sufficient strain energy in the alloy to ensure recrystallization, and statically recrystallizing the alloy. A grain structure exhibiting new, fine, equiaxed and uniform grains is produced in the alloy. An exemplary 6xxx alloy of the type capable of being produced by the present invention, and which is useful for aerospace, automotive and other applications, is disclosed and claimed. The process is also suitable for processing any age-hardenable aluminum or other alloy.

Superplastic Deformation Mechanisms of Superfine/Nanocrystalline Duplex PM-TiAl-Based Alloy

PubMed Central

Gong, Xuebo; Duan, Zhenxin; Pei, Wen; Chen, Hua

2017-01-01

In this paper, the equiaxed superfine/nanocrystalline duplex PM-TiAl-based alloy with (γ + α2) microstructure, Ti-45Al-5Nb (at %), has been synthesized by high-energy ball milling and vacuum hot pressing sintering. Superplastic deformation behavior has been investigated at 1000 °C and 1050 °C with strain rates from 5 × 10−5 s−1 to 1 × 10−3 s−1. The effects of deformation on the microstructure and mechanical behaviors of high Nb containing TiAl alloy have been characterized and analyzed. The results showed that, the ultimate tensile strength of the alloy was 58.7 MPa at 1000 °C and 10.5 MPa at 1050 °C with a strain rate of 5 × 10−5 s−1, while the elongation was 121% and 233%, respectively. The alloy exhibited superplastic elongation at 1000 and 1050 °C with an exponent (m) of 0.48 and 0.45. The main softening mechanism was dynamic recrystallization of γ grains; the dislocation slip and γ/γ interface twinning were responsible for superplastic deformation. The orientation relationship of γ/γ interface twinning obeyed the classical one: (001)γ//(110)γ. PMID:28925971

Superplastic Deformation Mechanisms of Superfine/Nanocrystalline Duplex PM-TiAl-Based Alloy.

PubMed

Gong, Xuebo; Duan, Zhenxin; Pei, Wen; Chen, Hua

2017-09-19

In this paper, the equiaxed superfine/nanocrystalline duplex PM-TiAl-based alloy with (γ + α₂) microstructure, Ti-45Al-5Nb (at %), has been synthesized by high-energy ball milling and vacuum hot pressing sintering. Superplastic deformation behavior has been investigated at 1000 °C and 1050 °C with strain rates from 5 × 10 -5 s -1 to 1 × 10 -3 s -1 . The effects of deformation on the microstructure and mechanical behaviors of high Nb containing TiAl alloy have been characterized and analyzed. The results showed that, the ultimate tensile strength of the alloy was 58.7 MPa at 1000 °C and 10.5 MPa at 1050 °C with a strain rate of 5 × 10 -5 s -1 , while the elongation was 121% and 233%, respectively. The alloy exhibited superplastic elongation at 1000 and 1050 °C with an exponent (m) of 0.48 and 0.45. The main softening mechanism was dynamic recrystallization of γ grains; the dislocation slip and γ/γ interface twinning were responsible for superplastic deformation. The orientation relationship of γ/γ interface twinning obeyed the classical one: (001) γ //(110) γ .

Low temperature superplasticity and thermal stability of a nanostructured low-carbon microalloyed steel

PubMed Central

Hu, J.; Du, L.-X.; Sun, G.-S.; Xie, H.; Misra, R.D.K.

2015-01-01

We describe here for the first time the low temperature superplasticity of nanostructured low carbon steel (microalloyed with V, N, Mn, Al, Si, and Ni). Low carbon nanograined/ultrafine-grained (NG/UFG) bulk steel was processed using a combination of cold-rolling and annealing of martensite. The complex microstructure of NG/UFG ferrite and 50–80 nm cementite exhibited high thermal stability at 500 °C with low temperature elongation exceeding 100% (at less than 0.5 of the absolute melting point) as compared to the conventional fine-grained (FG) counterpart. The low temperature superplasticity is adequate to form complex components. Moreover, the low strength during hot processing is favorable for decreasing the spring back and minimize die loss. PMID:26687012

Analysis of formability of Ca-added magnesium alloy sheets at low temperatures

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kim, Se-Jong; Lee, Young-Seon; Kim, Daeyong, E-mail: daeyong@kims.re.kr

The formability of sheets of the Ca-added magnesium alloy AZX311 was analyzed. The parameters affecting the sheet formability, such as the strain-hardening rate and the strain-rate sensitivity, did not seem to be higher in the alloy AZX311 at temperatures of room temperature (RT) and 200 °C. In addition, the critical stress for fracture at RT was lower in AZX311 than in AZ31. However, AZX311 exhibited higher stretchability and formability at low temperatures than AZ31. Electron back-scattered diffraction microscopy revealed that AZX311 had a weaker basal texture as well as broadened basal poles along the transverse direction. Polycrystal plasticity simulations confirmedmore » that this weaker basal texture increases the activity of basal slip over thickness strain, resulting in the higher formability of AZX311. - Highlights: • A weak basal texture with broadening basal poles along the TD in AZX311 • Lower critical stress for fracture at RT in AZX311 than in AZ31 • Lower strain-hardening rates at low temperatures in the AZX311 than in the AZ31 • Higher formability at low temperatures in AZX311 because of the weak basal texture.« less

Analysis of the Transition in Deformation Mechanisms in Superplastic 5083 Aluminum Alloys by Orientation Imaging Microscopy

DTIC Science & Technology

2001-09-01

Analysis of the Transition in Deformation Mechanisms in Superplastic 5083 Aluminum Alloys by Orientation Imaging Microscopy 6. AUTHOR( S ) Harrell...James W. 5. FUNDING NUMBERS 7. PERFORMING ORGANIZATION NAME( S ) AND ADDRESS(ES) Naval Postgraduate School Monterey, CA 93943-5000 8. PERFORMING...ORGANIZATION REPORT NUMBER 9. SPONSORING / MONITORING AGENCY NAME( S ) AND ADDRESS(ES) General Motors Corp., Research and Development Center

Formability of a wrought Mg alloy evaluated by impression testing

DOE Office of Scientific and Technical Information (OSTI.GOV)

Mohamed, Walid; Gollapudi, Srikant; Charit, Indrajit

This study is focused on furthering our understanding of the different factors that influence the formability of Magnesium alloys. Towards this end, formability studies were undertaken on a wrought Mg-2Zn-1Mn (ZM21) alloy. In contrast to conventional formability studies, the impression testing method was adopted here to evaluate the formability parameter, B, at temperatures ranging from 298 to 473 K. The variation of B of ZM21 with temperature and its rather limited values were discussed in the light of different deformation mechanisms such as activation of twinning, slip, grain boundary sliding (GBS) and dynamic recrystallization (DRX). It was found that themore » material characteristics such as grain size, texture and testing conditions such as temperature and strain rate, were key determinants of the mechanism of plastic deformation. A by-product of this analysis was the observation of an interesting correlation between the Zener-Hollomon parameter, Z, and the ability of Mg alloys to undergo DRX.« less

Tensile behaviors of three-dimensionally free-formable titanium mesh plates for bone graft applications

NASA Astrophysics Data System (ADS)

He, Jianmei

2017-11-01

Present metal artificial bones for bone grafts have the problems like too heavy and excessive elastic modulus compared with natural bones. In this study, three-dimensionally (3D) free-formable titanium mesh plates for bone graft applications was introduced to improve these problems. Fundamental mesh shapes and patterns were designed under different base shapes and design parameters through three dimensional CAD tools from higher flexibility and strength points of view. Based on the designed mesh shape and patterns, sample specimens of titanium mesh plates with different base shapes and design variables were manufactured through laser processing. Tensile properties of the sample titanium mesh plates like volume density, tensile elastic modulus were experimentally and analytically evaluated. Experimental results showed that such titanium mesh plates had much higher flexibility and their mechanical properties could be controlled to close to the natural bones. More details on the mechanical properties of titanium mesh plates including compression, bending, torsion and durability will be carried out in future study.

Influence of ECAP temperature on the formability of a particle reinforced 2017 aluminum alloy

NASA Astrophysics Data System (ADS)

Wagner, S.; Härtel, M.; Frint, P.; F-X Wagner, M.

2017-03-01

Severe plastic deformation methods are commonly used to increase the strength of materials by generating ultrafine-grained microstructures. The application of these methods to Al-Cu alloys is, however, difficult because of their poor formability at room temperature. An additional reduction of formability of such alloys occurs when ceramic particles are added as reinforcement: this often triggers shear localization and crack initiation during ECAP. This is the main reason why equal-channel angular pressing (ECAP) of aluminum matrix composites (AMCs) can generally only be performed at elevated temperatures and using ECAP dies with a channel angle larger than 90° (e.g. 120°). In this study we present a brief first report on an alternative approach for the improvement of the formability of an AMC (AA2017, 10 % SiC): ECAP at low temperatures. We show that, using a temperature of -60 °C and a channel angle of 90° (corresponding to an equivalent strain of 1.1), ECAP of the AMC can be successfully performed without material failure. The mechanical properties of the strongly deformed AMC are analyzed by tensile testing. Our results indicate that the increased formability of the AMC at low temperatures can be attributed to the suppression of unstable plastic flow that affects formability at room temperature.

Solid-state Bonding of Superplastic Aluminum Alloy 7475 Sheet

NASA Technical Reports Server (NTRS)

Byun, T. D. S.; Vastava, R. B.

1985-01-01

Experimental works were carried out to study the feasibility of solid state bonding of superplastic aluminum 7475 sheet. Amount of deformation, bonding time, surface cleaning method and intermediate layer were the process parameters investigated. Other parameters, held constant by the superplastic forming condition which is required to obtain a concurrent solid state bonding, are bonding temperature, bonding pressure and atmosphere. Bond integrity was evaluated through metallographic examination, X-ray line scan analysis, SEM fractographic analysis and lap shear tests. The early results of the development program indicated that sound solid state bonding was accomplished for this high strength 7475 alloy with significant amounts of deformation. A thin intermediate layer of the soft 5052 aluminum alloy aided in achieving a solid state bonding by reducing the required amount of plastic deformation at the interface. Bond strength was substantially increased by a post bond heat treatment.

Transition from poor ductility to room-temperature superplasticity in a nanostructured aluminum alloy.

PubMed

Edalati, Kaveh; Horita, Zenji; Valiev, Ruslan Z

2018-04-30

Recent developments of nanostructured materials with grain sizes in the nanometer to submicrometer range have provided ground for numerous functional properties and new applications. However, in terms of mechanical properties, bulk nanostructured materials typically show poor ductility despite their high strength, which limits their use for structural applications. The present article shows that the poor ductility of nanostructured alloys can be changed to room-temperature superplastisity by a transition in the deformation mechanism from dislocation activity to grain-boundary sliding. We report the first observation of room-temperature superplasticity (over 400% tensile elongations) in a nanostructured Al alloy by enhanced grain-boundary sliding. The room-temperature grain-boundary sliding and superplasticity was realized by engineering the Zn segregation along the Al/Al boundaries through severe plastic deformation. This work introduces a new boundary-based strategy to improve the mechanical properties of nanostructured materials for structural applications, where high deformability is a requirement.

High Temperature Mechanical Behavior of Polycrystalline Alumina from Mixed Nanometer and Micrometer Powders

NASA Technical Reports Server (NTRS)

Goldsby, Jon C.

2001-01-01

Sintered aluminum oxide materials were formed using commercial methods from mechanically mixed powders of nano-and micrometer alumina. The powders were consolidated at 1500 and 1600 C with 3.2 and 7.2 ksi applied stress in argon. The conventional micrometer sized powders failed to consolidate. While 100 percent nanometer-sized alumina and its mixture with the micrometer powders achieved less than 99 percent density. Preliminary high temperature creep behavior indicates no super-plastic strains. However high strains (less than 0.65 percent) were generated in the nanometer powder, due to cracks and linked voids initiated by cavitation.

Numerical assessment of residual formability in sheet metal products: towards design for sustainability

NASA Astrophysics Data System (ADS)

Falsafi, Javad; Demirci, Emrah; Silberschmidt, Vadim. V.

2016-08-01

A new computational scheme is presented to addresses cold recyclability of sheet- metal products. Cold recycling or re-manufacturing is an emerging area studied mostly empirically; in its current form, it lacks theoretical foundation especially in the area of sheet metals. In this study, a re-formability index was introduced based on post-manufacture residual formability in sheet metal products. This index accounts for possible levels of deformation along different strain paths based on Polar Effective Plastic Strain (PEPS) technique. PEPS is strain-path independent, hence provides a foundation for residual formability analysis. A user- friendly code was developed to implement this assessment in conjunction with advanced finite- element (FE) analysis. The significance of this approach is the advancement towards recycling of sheet metal products without melting them.

Comparison of microstructure of superplastically deformed synthetic materials and ultramylonite: Coalescence of secondary mineral grains via grain boundary sliding

NASA Astrophysics Data System (ADS)

Hiraga, T.; Miyazaki, T.; Tasaka, M.; Yoshida, H.

2011-12-01

Using very fine-grained aggregates of forsterite containing ~10vol% secondary mineral phase such as periclase and enstatite, we have been able to demonstrate their superplascity, that is, achievement of more than a few 100 % tensile strain (Hiraga et al. 2010). Superplastic deformation is commonly considered to proceed via grain boundary sliding (GBS) which results in grain switching in the samples. Hiraga et al. (2010) succeeded in detecting the operation of GBS from observing the coalescence of grains of secondary phase in superplastically deformed samples. The secondary phase pins the motion of grain boundaries of the primary phase; however, the reduction of the number of the grains of secondary phase due to their coalescence allows grain growth of the primary phase. We analyzed the relationships between grain size of the primary and secondary phases, between strain and grain size, and between strain and the number of coalesced grains in the superplastically deformed samples. The results supports participation of all the grains of the primary phase in grain switching process indicating that the grain boundary sliding accommodates almost entire strain during the deformation. Mechanical properties of these materials such as their stress and grain size exponents of 1-2 do not conflict this conclusion. We applied the relationships obtained from analyzing superplastic materials to the microstructure of the natural samples, which has been considered to have deformed via grain boundary sliding, that is, ultramylonite. The microstructure of greenschist-grade ultramylonite reported by Fliervoet et al. (1997) was analyzed. Distributions of the mineral phases (i.e., quartz, plagioclase, K-feldspar and biotite) show distinct coalescence of the same mineral phases in the direction almost perpendicular to the foliation of the rock. The number of coalesced grains indicates that the strain that rock experienced is > 2. [reference] Hiraga et al. (2010) Nature 468, 1091-1094; Fliervoet et al. (1997) Journal of Structural Geology 19, 1495-1520

Assessing the formability of metallic sheets by means of localized and diffuse necking models

NASA Astrophysics Data System (ADS)

Comşa, Dan-Sorin; Lǎzǎrescu, Lucian; Banabic, Dorel

2016-10-01

The main objective of the paper consists in elaborating a unified framework that allows the theoretical assessment of sheet metal formability. Hill's localized necking model and the Extended Maximum Force Criterion proposed by Mattiasson, Sigvant, and Larsson have been selected for this purpose. Both models are thoroughly described together with their solution procedures. A comparison of the theoretical predictions with experimental data referring to the formability of a DP600 steel sheet is also presented by the authors.

Superplasticity - A Fundamental Investigation on Deformation Mechanism and Cavitation Phenomena.

DTIC Science & Technology

1988-02-15

NI-MODIFIED SUPERPLASTIC Ti- 6Al - 4V ALLOY, B. Hidalgo-Prada and A.K. Mukherjee, Proc. of Intnl. Conf. of Strength of Metals and AlloyS-7, Montreal...features, e.g., initial porosity (15 to 500 pm diam.), stringers (of Fe-rich particles, 5-30 pm diam.), and small (0.3-3 pm) copper- rich particles...500% or greater, porosity between grains was observed. Some grains as well as grain clusters are visible in Fig. 6. The grain clusters are believed to

Study of Cavitation and Failure Mechanisms of a Superplastic 5083 Aluminum Alloy

DTIC Science & Technology

2003-09-01

Failure Mechanisms of a Superplastic 5083 Aluminum Alloy 6. AUTHOR( S ) Boydon, Juanito F. 5. FUNDING NUMBERS 7. PERFORMING ORGANIZATION NAME( S ) AND...NAME( S ) AND ADDRESS(ES) General Motors Corp., Research and Development Center, Warren, MI (Dr. Paul E. Krajewski, Technical Program...of 973931(A3), deformed gauge area 1- region 1. Sample was pulled under uniaxial tension at 450 °C at a strain rate of 3x10-4 s -1 and elongated to

Single point incremental forming: Formability of PC sheets

NASA Astrophysics Data System (ADS)

Formisano, A.; Boccarusso, L.; Carrino, L.; Lambiase, F.; Minutolo, F. Memola Capece

2018-05-01

Recent research on Single Point Incremental Forming of polymers has slightly covered the possibility of expanding the materials capability window of this flexible forming process beyond metals, by demonstrating the workability of thermoplastic polymers at room temperature. Given the different behaviour of polymers compared to metals, different aspects need to be deepened to better understand the behaviour of these materials when incrementally formed. Thus, the aim of the work is to investigate the formability of incrementally formed polycarbonate thin sheets. To this end, an experimental investigation at room temperature was conducted involving formability tests; varying wall angle cone and pyramid frusta were manufactured by processing polycarbonate sheets with different thicknesses and using tools with different diameters, in order to draw conclusions on the formability of polymer sheets through the evaluation of the forming angles and the observation of the failure mechanisms.

Effect of anisotropy on mechanical properties of Ti-6Al-4V in superplastic region

NASA Astrophysics Data System (ADS)

Wahed, MA; Gupta, AK; Singh, SK; Kotkunde, N.

2018-04-01

This paper presents an experimental investigation on the flow stress behaviour of Ti-6Al-4V alloy at elevated temperatures and very low strain rate. Though Ti-6Al-4V alloy is very hard to deform at room temperature, having only about 16 % elongation, it exhibits super-plasticity at elevated temperatures. To investigate this, the tensile tests were conducted from 700°C to 900°C temperatures at an interval of 50°C and at a very low strain rate 0.0001/s along three different directions: rolling direction, 45° to rolling direction and transverse direction. The experimental study shows more than 50% elongation in all the cases and particularly more than 250% elongation at 0.0001 / s strain rate and at 750°C to 900°C temperature in all directions, which is an indication of super-plasticity in the material. This is also corroborated by the microstructural study of the fractured specimens.

High temperature tensile and creep behaviour of low pressure plasma-sprayed Ni-Co-Cr-Al-Y coating alloy

NASA Technical Reports Server (NTRS)

Hebsur, M. G.; Miner, R. V.

1986-01-01

The high temperature tensile and creep behavior of low pressure plasma-sprayed plates of a typical Ni-Co-Cr-Al-Y alloy has been studied. From room temperature to 800 K, the Ni-Co-Cr-Al-Y alloy studied has nearly a constant low ductility and a high strength. At higher temperatures, it becomes weak and highly ductile. At and above 1123 K, the behavior is highly dependent on strain rate and exhibits classic superplastic characteristics with a high ductility at intermediate strain rates and a strain rate sensitivity of about 0.5. At either higher or lower strain rates, the ductility decreases and the strain rate sensitivities are about 0.2. In the superplastic deformation range, the activation energy for creep is 120 + or - 20 kJ/mol, suggesting a diffusion-aided grain boundary sliding mechanism. Outside the superplastic range, the activation energy for creep is calculated to be 290 + or - 20 kJ/mol.

Formability analysis of sheet metals by cruciform testing

NASA Astrophysics Data System (ADS)

Güler, B.; Alkan, K.; Efe, M.

2017-09-01

Cruciform biaxial tests are increasingly becoming popular for testing the formability of sheet metals as they achieve frictionless, in-plane, multi-axial stress states with a single sample geometry. However, premature fracture of the samples during testing prevents large strain deformation necessary for the formability analysis. In this work, we introduce a miniature cruciform sample design (few mm test region) and a test setup to achieve centre fracture and large uniform strains. With its excellent surface finish and optimized geometry, the sample deforms with diagonal strain bands intersecting at the test region. These bands prevent local necking and concentrate the strains at the sample centre. Imaging and strain analysis during testing confirm the uniform strain distributions and the centre fracture are possible for various strain paths ranging from plane-strain to equibiaxial tension. Moreover, the sample deforms without deviating from the predetermined strain ratio at all test conditions, allowing formability analysis under large strains. We demonstrate these features of the cruciform test for three sample materials: Aluminium 6061-T6 alloy, DC-04 steel and Magnesium AZ31 alloy, and investigate their formability at both the millimetre scale and the microstructure scale.

Increasing the formability of ferritic stainless steel tube by granular medium-based hot forming

NASA Astrophysics Data System (ADS)

Chen, H.; Staupendahl, D.; Hiegemann, L.; Tekkaya, A. E.

2017-09-01

Ferritic stainless steel without the alloy constituent nickel is an economical substitution for austenitic stainless steel in the automotive industry. Its lower formability, however, oftentimes prevents the direct material substitution in forming processes such as hydroforming, necessitating new forming strategies. To extend the forming capacity of ferritic stainless steel tube, the approach of forming at elevated temperatures is proposed. Utilizing granular material as forming medium, high forming temperatures up to 900°C are realized. The forming process works by moving punches axially into the granular medium, thereby, compressing it and causing axial as well as radial pressure. In experimental and numerical investigations it is shown that interfacial friction between the granular medium and the tube inherently causes tube feed, resulting in stain states in the tension-compression region of the FLD. Formability data for this region are gained by notched tensile tests, which are performed at room temperature as well as at elevated temperatures. The measured data show that the formability is improved at forming temperatures higher than 700°C. This observed formability increase is experimentally validated using a demonstrator geometry, which reaches expansion ratios that show fracture in specimens formed at room temperature.

Strength and Formability Improvement of Al-Cu-Mn Aluminum Alloy Complex Parts by Thermomechanical Treatment with Sheet Hydroforming

NASA Astrophysics Data System (ADS)

Chen, Yi-Zhe; Liu, Wei; Yuan, Shi-Jian

2015-05-01

Normally, the strength and formability of aluminum alloys can be increased largely by severe plastic deformation and heat treatment. However, many plastic deformation processes are more suitable for making raw material, not for formed parts. In this article, an experimental study of the thermomechanical treatment by using the sheet hydroforming process was developed to improve both mechanical strength and formability for aluminum alloys in forming complex parts. The limiting drawing ratio, thickness, and strain distribution of complex parts formed by sheet hydroforming were investigated to study the formability and sheet-deformation behavior. Based on the optimal formed parts, the tensile strength, microhardness, grain structure, and strengthening precipitates were analyzed to identify the strengthening effect of thermomechanical treatment. The results show that in the solution state, the limiting drawing ratio of cylindrical parts could be increased for 10.9% compared with traditional deep drawing process. The peak values of tensile stress and microhardness of formed parts are 18.0% and 12.5% higher than that in T6 state. This investigation shows that the thermomechanical treatment by sheet hydroforming is a potential method for the products manufacturing of aluminum alloy with high strength and good formability.

Experimental study on the warm forming and quenching behavior for hot stamping of high-strength aluminum alloys

NASA Astrophysics Data System (ADS)

Degner, J.; Horn, A.; Merklein, M.

2017-09-01

Within the last decades, stringent regulations on fuel consumption, CO2 emissions and product recyclability forced the automotive sector to implement new strategies within the field of car body manufacturing. Due to their low density and good corrosion resistance, aluminum became one of the most relevant lightweight materials. Recently, especially high- strength aluminum alloys for structural components gained importance. Since the low formability of these alloys limits their application, there is a need for novel process strategies in order to enhance the forming behavior. One promising approach is the hot stamping of aluminum alloys. The combination of quenching and forming in one step after solution heat treatment leads to a significant improvement of the formability. Furthermore, higher manufacturing accuracy can be achieved due to reduced spring back. Within this contribution, the influence of forming temperature on the subsequent material behavior and the heat transfer during quenching will be analyzed. Therefore, the mechanical and thermal material characteristics such as flow behavior and heat transfer coefficient during hot stamping are investigated.

Analysis of Square Cup Deep-Drawing Test of Pure Titanium

NASA Astrophysics Data System (ADS)

Ogawa, Takaki; Ma, Ninshu; Ueyama, Minoru; Harada, Yasunori

2016-08-01

The prediction of formability of titunium is more difficult than steels since its strong anisotropy. If computer simulation can estimate the formability of titanium, we can select the optimal forming conditions. The purpose of this study was to acquire knowledge for the formability prediction by the computer simulation of the square cup deep-drawing of pure titanium. In this paper, the results of FEM analsis of pure titanium were compared with the experimental results to examine the analysis validity. We analyzed the formability of deepdrawing square cup of titanium by the FEM using solid elements. Compared the analysis results with the experimental results such as the forming shape, the punch load, and the thickness, the validity was confirmed. Further, through analyzing the change of the thickness around the forming corner, it was confirmed that the thickness increased to its maximum value during forming process at the stroke of 35mm more than the maximum stroke.

Investigation of the formability of aluminium alloys at elevated temperatures

NASA Astrophysics Data System (ADS)

Tisza, M.; Budai, D.; Kovács, P. Z.; Lukács, Zs

2016-11-01

Aluminium alloys are more and more widely applied in car body manufacturing. Increasing the formability of aluminium alloys are one of the most relevant tasks in todays’ research topics. In this paper, the focus will be on the investigation of the formability of aluminium alloys concerning those material grades that are more widely applied in the automotive industry including the 5xxx and 6xxx aluminium alloy series. Recently, besides the cold forming of aluminium sheets the forming of aluminium alloys at elevated temperatures became a hot research topic, too. In our experimental investigations, we mostly examined the EN AW 5754 and EN AW 6082 aluminium alloys at elevated temperatures. We analysed the effect of various material and process parameters (e.g. temperature, sheet thickness) on the formability of aluminium alloys with particular emphasis on the Forming Limit Diagrams at elevated temperatures in order to find the optimum forming conditions for these alloys.

Development of near β titanium alloy with high strength and superplastic properties

NASA Astrophysics Data System (ADS)

Naydenkin, E. V.; Ratochka, I. V.; Mishin, I. P.; Lykova, O. N.

2017-12-01

Ultrafine-grained (UFG) structure with an average element size of about 0.25 µm was obtained in a near β titanium alloy under severe plastic deformation by abc pressing. It is shown that the formation of such structure greatly increases the ultimate strength of the alloy compared to its coarse-grained state (up to 1610 MPa). In addition, the UFG alloy features improved superplastic characteristics under tension at temperatures of 973-1073 K: its elongation to failure exceeds 1300% and the flow stress decreases to several MPa.

Formability of new high performance A710 grade 50 structural steel.

DOT National Transportation Integrated Search

2014-01-01

This project compared the formability of modified ASTM A710 Grade B50 ksi yield strength steel, jointly developed by : Northwestern University and the Illinois Department of Transportation, with ASTM A606 Type 4 weathering steel used in Illinois : an...

Deep drawability of Ti/resin/Ti laminated sheet

NASA Astrophysics Data System (ADS)

Hardada, Yasunroi; Hattori, Shuji

2017-10-01

Aiming to enhance functionality of titanium cup, the formability of titanium/resin/titanium laminated sheet by deep drawing was investigated. Although pure titanium has excellent corrosion resistance, the density of titanium is higher than that of light metals, such as aluminum and magnesium. Part of the titanium cup made of resin allows for weight reduction of the cup. Furthermore, the clad cup is more likely to have heat retention and protection against vibration characteristics. In the experiment, the materials were pure titanium and polycarbonate. The initial thickness of the sheet was 0.2 to 0.5 mm in thickness. A total plate thickness of the blank was 1.0 to 1.5 mm in thickness. The blank diameter is 70 mm. The laminated sheet was constituted by interposing resin between two titanium sheets. Each sheet in stacked condition was not joined each other. In the deep drawing process, the laminated sheet was employed and a flat sheet blank was formed into a circle by a punch. For the prevention of seizure in contact area between a drawing tool and titanium, titanium blank was treated by oxide coating. By this method, the fresh and clean titanium is not in direct contact with the die during the forming due to the existence of the oxide layer. The deep drawing was carried out to investigate the formability. The laminated sheet was successfully drawn without the cracks. The section of the drawn cup was observed to examine a formability of the resin sheet. The reduction rate of the thickness was less than 10%. It was found that the titanium/resin/titanium clad cup was successfully drawn.

Variation of strain rate sensitivity index of a superplastic aluminum alloy in different testing methods

NASA Astrophysics Data System (ADS)

Majidi, Omid; Jahazi, Mohammad; Bombardier, Nicolas; Samuel, Ehab

2017-10-01

The strain rate sensitivity index, m-value, is being applied as a common tool to evaluate the impact of the strain rate on the viscoplastic behaviour of materials. The m-value, as a constant number, has been frequently taken into consideration for modeling material behaviour in the numerical simulation of superplastic forming processes. However, the impact of the testing variables on the measured m-values has not been investigated comprehensively. In this study, the m-value for a superplastic grade of an aluminum alloy (i.e., AA5083) has been investigated. The conditions and the parameters that influence the strain rate sensitivity for the material are compared with three different testing methods, i.e., monotonic uniaxial tension test, strain rate jump test and stress relaxation test. All tests were conducted at elevated temperature (470°C) and at strain rates up to 0.1 s-1. The results show that the m-value is not constant and is highly dependent on the applied strain rate, strain level and testing method.

Correlation of microstructure, tensile properties and hole expansion ratio in cold rolled advanced high strength steels

NASA Astrophysics Data System (ADS)

Terrazas, Oscar R.

The demand for advanced high strength steels (AHSS) with higher strengths is increasing in the automotive industry. While there have been major improvements recently in the trade-off between ductility and strength, sheared-edge formability of AHSS remains a critical issue. AHSS sheets exhibit cracking during stamping and forming operations below the predictions of forming limits. It has become important to understand the correlation between microstructure and sheared edge formability. The present work investigates the effects of shearing conditions, microstructure, and tensile properties on sheared edge formability. Seven commercially produced steels with tensile strengths of 1000 +/- 100 MPa were evaluated: five dual-phase (DP) steels with different compositions and varying microstructural features, one trip aided bainitic ferrite (TBF) steel, and one press-hardened steel tempered to a tensile strength within the desired range. It was found that sheared edge formability is influenced by the martensite in DP steels. Quantitative stereology measurements provided results that showed martensite size and distribution affect hole expansion ratio (HER). The overall trend is that HER increases with more evenly dispersed martensite throughout the microstructure. This microstructure involves a combination of martensite size, contiguity, mean free distance, and number of colonies per unit area. Additionally, shear face characterization showed that the fracture and burr region affect HER. The HER decreases with increasing size of fracture and burr region. With a larger fracture and burr region more defects and/or micro-cracks will be present on the shear surface. This larger fracture region on the shear face facilitates cracking in sheared edge formability. Finally, the sheared edge formability is directly correlated to true fracture strain (TFS). The true fracture strain from tensile samples correlates to the HER values. HER increases with increasing true fracture strain.

Experimental Investigations on Formability of Aluminum Tailor Friction Stir Welded Blanks in Deep Drawing Process

NASA Astrophysics Data System (ADS)

Kesharwani, R. K.; Panda, S. K.; Pal, S. K.

2015-02-01

In the present work, tailor friction stir welded blanks (TFSWBs) were fabricated successfully using 2.0-mm-thick AA5754-H22 and AA5052-H32 sheet metals with optimized tool design and process parameters. Taguchi L9 orthogonal array has been used to design the friction stir welding experiments, and the Grey relational analysis has been applied for the multi objective optimization in order to maximize the weld strength and total elongation reducing the surface roughness and energy consumption. The formability of the TFSWBs and parent materials was evaluated and compared in terms of limiting drawing ratio (LDR) using a conventional circular die. It was found that the formability of the TFSWBs was comparable with that of both the parent materials without failure in the weldment. A modified conical tractrix die (MCTD) was proposed to enhance the LDR of the TFSWBs. It was found that the formability was improved by 27% using the MCTD.

Direct Scaffolding of Biomimetic Hydroxyapatite-gelatin Nanocomposites using Aminosilane Cross-linker for Bone Regeneration

PubMed Central

Chiu, Chi-Kai; Ferreira, Joao; Luo, Tzy-Jiun M.; Geng, Haixia; Lin, Feng-Chang; Ko, Ching-Chang

2012-01-01

Hydroxyapatite-gelatin modified siloxane (GEMOSIL) nanocomposite was developed by coating, kneading and hardening processes to provide formable scaffolding for alloplastic graft applications. The present study aims to characterize scaffolding formability and mechanical properties of GEMOSIL, and to test the in vitro and in vivo biocompatibility of GEMOSIL. Buffer Solution initiated formable paste followed by the sol-gel reaction led to a final hardened composite. Results showed the adequate coating of aminosilane, 11–19 wt%, affected the cohesiveness of the powders and the final compressive strength (69 MPa) of the composite. TGA and TEM results showed the effective aminosilane coating that preserves hydroxyapatite-gelatin nanocrystals from damage. Both GEMOSIL with and without titania increased the mineralization of preosteoblasts in vitro. Only did titania additives revealed good in vivo bone formation in rat calvarium defects. The scaffolding formability, due to cohesive bonding among GEMOSIL particles, could be further refined to fulfill the complicated scaffold processes. PMID:22669282

Low Temperature Superplasticity of Ti-6Al-4V Processed by Warm Multidirectional Forging (Preprint)

DTIC Science & Technology

2012-07-01

microstructure in the two-phase titanium alloy Ti- 6Al - 4V . A microstructure with a grain size of 135 nm was attained, enabling low-temperature...the / titanium alloy Ti- 6Al - 4V [3]. The great interest in microstructure refinement is associated with significantly reduced superplastic (SP...consisted of the / titanium alloy Ti- 6Al - 4V with a nominal composition (in weight pct.) of 6.3 Al, 4.1 V, 0.18 Fe, 0.03 Si, 0.02 Zr, 0.01 C, 0.18 O, 0.01 N

Conference Proceedings of the Meeting of the Structures and Materials Panel of AGARD (67th) on New Light Alloys, Held in Mierlo, Netherlands on 3-5 October 1988

DTIC Science & Technology

1989-08-01

solution heat treatment. Before anodizing, acid (e.g. suilfochromic) etching is preferable to caustic etching. As observed on 8090, the attack doe to the...differences in preferred crystallographic orientation. From the 1111) pole figures in Fig. 19 it is evident that the texture is much more pronounced in the... Ridley , N., "Cavitation and superplasticity", SUPERPLASTICITY, AGARD-LS-154, Aug. 1987, Paper No. 4. 11. Lane, P.L., Gray, J.A., and Smith, C.J.E

Evaluation of factors affecting the edge formability of two hot rolled multiphase steels

NASA Astrophysics Data System (ADS)

Mukherjee, Monideepa; Tiwari, Sumit; Bhattacharya, Basudev

2018-02-01

In this study, the effect of various factors on the hole expansion ratio and hence on the edge formability of two hot rolled multiphase steels, one with a ferrite-martensite microstructure and the other with a ferrite-bainite microstructure, was investigated through systematic microstructural and mechanical characterization. The study revealed that the microstructure of the steels, which determines their strain hardening capacity and fracture resistance, is the principal factor controlling edge formability. The influence of other factors such as tensile strength, ductility, anisotropy, and thickness, though present, are secondary. A critical evaluation of the available empirical models for hole expansion ratio prediction is also presented.

Influences on the formability and mechanical properties of 7000-aluminum alloys in hot and warm forming

NASA Astrophysics Data System (ADS)

Behrens, B.-A.; Nürnberger, F.; Bonk, C.; Hübner, S.; Behrens, S.; Vogt, H.

2017-09-01

Aluminum alloys of the 7000 series possess high lightweight potential due to their high specific tensile strength combined with a good ultimate elongation. For this reason, hot-formed boron-manganese-steel parts can be substituted by these alloys. Therefore, the application of these aluminum alloys for structural car body components is desired to decrease the weight of the body in white and consequently CO2 emissions during vehicle operation. These days, the limited formability at room temperature limits an application in the automobile industry. By increasing the deformation temperature, formability can be improved. In this study, two different approaches to increase the formability of these alloys by means of higher temperatures were investigated. The first approach is a warm forming route to form sheets in T6 temper state with high tensile strength at temperatures between 150 °C and 300 °C. The second approach is a hot forming route. Here, the material is annealed at solution heat treatment temperature and formed directly after the annealing step. Additionally, a quench step is included in the forming stage. After the forming and quenching step, the sheets have to be artificially aged to achieve the high specific tensile strength. In this study, several parameters in the presented process routes, which influence the formability and the mechanical properties, have been investigated for the aluminum alloys EN AW7022 and EN AW7075.

The deformation behavior and microstructure evolution of duplex Mg-9Li-1Al alloy during superplasticity tensile testing

NASA Astrophysics Data System (ADS)

Liu, Meiduo; Zheng, Haipeng; Zhang, Tianlong; Wu, Ruizhi

2017-12-01

The superplastic mechanical properties and microstructure evolution of the duplex Mg-9Li-1Al alloy were investigated. The tensile testing results show that, the elongation of the as-extruded Mg-9Li-1Al alloy reaches 510% at 573 K with a strain rate of 2×10-4 s-1. During the deformation process, the strips of α phase break into equiaxed structure. This phenomenon can be attributed to a particular dynamic recrystallization, which suggests that the β phase can recrystallize in the α phase due to the small misfit degree between α phase and β phase.

Assessment of the Critical Parameters Influencing the Edge Stretchability of Advanced High-Strength Steel Sheet

NASA Astrophysics Data System (ADS)

Pathak, N.; Butcher, C.; Worswick, M.

2016-11-01

The edge formability of ferritic-martensitic DP (dual-phase) and ferritic-bainitic CP (complex-phase) steels was evaluated using a hole expansion test for different edge conditions. Hole expansion tests involving the standard conical punch as well as a custom flat punch were performed to investigate formability when the hole is expanded out-of-plane (conical punch) and in-plane using the flat punch. A range of edge conditions were considered, in order to isolate the influence of a range of factors thought to influence edge formability. The results demonstrate that work hardening and void damage at the sheared edge govern formability, while the sheared surface quality plays a minor or secondary role. A comparison of the edge stretching limits of DP and CP steels demonstrates the advantages of a ferritic-bainitic microstructure for forming operations with severe local deformation as in a stretch-flanging operation. A comparison of a traditional DP780 steel with a CP steel of similar strength showed that the edge stretching limit of the CP steel was three times larger than that of the DP780.

Super-formable pure magnesium at room temperature.

PubMed

Zeng, Zhuoran; Nie, Jian-Feng; Xu, Shi-Wei; H J Davies, Chris; Birbilis, Nick

2017-10-17

Magnesium, the lightest structural metal, is difficult to form at room temperature due to an insufficient number of deformation modes imposed by its hexagonal structure and a strong texture developed during thermomechanical processes. Although appropriate alloying additions can weaken the texture, formability improvement is limited because alloying additions do not fundamentally alter deformation modes. Here we show that magnesium can become super-formable at room temperature without alloying. Despite possessing a strong texture, magnesium can be cold rolled to a strain at least eight times that possible in conventional processing. The resultant cold-rolled sheet can be further formed without cracking due to grain size reduction to the order of one micron and inter-granular mechanisms becoming dominant, rather than the usual slip and twinning. These findings provide a pathway for developing highly formable products from magnesium and other hexagonal metals that are traditionally difficult to form at room temperature.Replacing steel or aluminium vehicle parts with magnesium would result in reduced emissions, but shaping magnesium without cracking remains challenging. Here, the authors successfully extrude and roll textured magnesium into ductile foil at low temperatures by activating intra-granular mechanisms.

Superplastic Creep of Metal Nanowires From Rate-Dependent Plasticity Transition

DOE PAGES

Tao, Weiwei; Cao, Penghui; Park, Harold S.

2018-04-30

Understanding the time-dependent mechanical behavior of nanomaterials such as nanowires is essential to predict their reliability in nanomechanical devices. This understanding is typically obtained using creep tests, which are the most fundamental loading mechanism by which the time dependent deformation of materials is characterized. However, due to existing challenges facing both experimentalists and theorists, the time dependent mechanical response of nanowires is not well-understood. Here, we use atomistic simulations that can access experimental time scales to examine the creep of single-crystal face-centered cubic metal (Cu, Ag, Pt) nanowires. Here, we report that both Cu and Ag nanowires show significantly increasedmore » ductility and superplasticity under low creep stresses, where the superplasticity is driven by a rate-dependent transition in defect nucleation from twinning to trailing partial dislocations at the micro- or millisecond time scale. The transition in the deformation mechanism also governs a corresponding transition in the stress-dependent creep time at the microsecond (Ag) and millisecond (Cu) time scales. Overall, this work demonstrates the necessity of accessing time scales that far exceed those seen in conventional atomistic modeling for accurate insights into the time-dependent mechanical behavior and properties of nanomaterials.« less

Cavitation During Superplastic Forming

PubMed Central

Campbell, John

2011-01-01

Cavitation is the opening of pores during superplastic forming, typically at grain boundary triple points or on second phase grain boundary particles during slip of grain boundaries. Theories for the initiation of cavitation are reviewed. It seems that cavitation is unlikely to occur by processes intrinsic to metals such as dislocation mechanisms or point defect condensation. It is proposed that cavitation can only occur at non-bonded interfaces such as those introduced extrinsically (i.e., from the outside) during the original casting of the metal. These defects, known as oxide bifilms, are naturally introduced during pouring of the liquid metal, and are frozen into the solid, often pushed by dendritic growth into grain boundaries where they are difficult to detect because of their extreme thinness, often measured in nanometres. Their unbonded central interface acts as a crack and can initiate cavitation. Second phase precipitates probably do not nucleate and grow on grain boundaries but grow on bifilms in the boundaries, explaining the apparent association between boundaries, second phase particles and failure initiation. Improved melting and casting techniques can provide metal with reduced or zero bifilm population for which cavitation would not be possible, promising significant improvements in superplastic behaviour. PMID:28824142

Cavitation During Superplastic Forming.

PubMed

Campbell, John

2011-07-08

Cavitation is the opening of pores during superplastic forming, typically at grain boundary triple points or on second phase grain boundary particles during slip of grain boundaries. Theories for the initiation of cavitation are reviewed. It seems that cavitation is unlikely to occur by processes intrinsic to metals such as dislocation mechanisms or point defect condensation. It is proposed that cavitation can only occur at non-bonded interfaces such as those introduced extrinsically (i.e., from the outside) during the original casting of the metal. These defects, known as oxide bifilms, are naturally introduced during pouring of the liquid metal, and are frozen into the solid, often pushed by dendritic growth into grain boundaries where they are difficult to detect because of their extreme thinness, often measured in nanometres. Their unbonded central interface acts as a crack and can initiate cavitation. Second phase precipitates probably do not nucleate and grow on grain boundaries but grow on bifilms in the boundaries, explaining the apparent association between boundaries, second phase particles and failure initiation. Improved melting and casting techniques can provide metal with reduced or zero bifilm population for which cavitation would not be possible, promising significant improvements in superplastic behaviour.

Superplastic Creep of Metal Nanowires from Rate-Dependent Plasticity Transition.

PubMed

Tao, Weiwei; Cao, Penghui; Park, Harold S

2018-05-22

Understanding the time-dependent mechanical behavior of nanomaterials such as nanowires is essential to predict their reliability in nanomechanical devices. This understanding is typically obtained using creep tests, which are the most fundamental loading mechanism by which the time-dependent deformation of materials is characterized. However, due to existing challenges facing both experimentalists and theorists, the time-dependent mechanical response of nanowires is not well-understood. Here, we use atomistic simulations that can access experimental time scales to examine the creep of single-crystal face-centered cubic metal (Cu, Ag, Pt) nanowires. We report that both Cu and Ag nanowires show significantly increased ductility and superplasticity under low creep stresses, where the superplasticity is driven by a rate-dependent transition in defect nucleation from twinning to trailing partial dislocations at the micro- or millisecond time scale. The transition in the deformation mechanism also governs a corresponding transition in the stress-dependent creep time at the microsecond (Ag) and millisecond (Cu) time scales. Overall, this work demonstrates the necessity of accessing time scales that far exceed those seen in conventional atomistic modeling for accurate insights into the time-dependent mechanical behavior and properties of nanomaterials.

Superplastic Creep of Metal Nanowires From Rate-Dependent Plasticity Transition

DOE Office of Scientific and Technical Information (OSTI.GOV)

Tao, Weiwei; Cao, Penghui; Park, Harold S.

Understanding the time-dependent mechanical behavior of nanomaterials such as nanowires is essential to predict their reliability in nanomechanical devices. This understanding is typically obtained using creep tests, which are the most fundamental loading mechanism by which the time dependent deformation of materials is characterized. However, due to existing challenges facing both experimentalists and theorists, the time dependent mechanical response of nanowires is not well-understood. Here, we use atomistic simulations that can access experimental time scales to examine the creep of single-crystal face-centered cubic metal (Cu, Ag, Pt) nanowires. Here, we report that both Cu and Ag nanowires show significantly increasedmore » ductility and superplasticity under low creep stresses, where the superplasticity is driven by a rate-dependent transition in defect nucleation from twinning to trailing partial dislocations at the micro- or millisecond time scale. The transition in the deformation mechanism also governs a corresponding transition in the stress-dependent creep time at the microsecond (Ag) and millisecond (Cu) time scales. Overall, this work demonstrates the necessity of accessing time scales that far exceed those seen in conventional atomistic modeling for accurate insights into the time-dependent mechanical behavior and properties of nanomaterials.« less

Superplasticity of Annealed H13 Steel

PubMed Central

Duan, Zhenxin; Pei, Wen; Gong, Xuebo; Chen, Hua

2017-01-01

H13 steel is a widely used hot work die material. A new type of hot working method is imperative to develop complex and precise dies. In this paper, the heat treatment of H13 steel (AISI) was carried out by annealing, the final structure is a point or spherical pearlite, and the grain size is about 30–40 μm. The tensile properties of the annealed microstructure were investigated at 650, 750, and 850 °C with the strain rates of 1 × 10−3 s−1, 5 × 10−4 s−1, and 1 × 10−4 s−1. The tensile fracture and microstructure were analyzed by SEM and HREM. The results show that the tensile samples reach superplasticity at the strain rate of 1 × 10−4 s−1 in the temperature range of 750–850 °C. When the temperature is 850 °C, the maximum elongation rate reaches 112.5%. This demonstrates the possibility of making superplastic forming molds. During the tensile process, the refined M23C6 and other high hardness carbides which are dispersed uniformly in the matrix, effectively inhibits grain growth and hinders dislocation movement, leading to the improvement of plasticity. PMID:28773231

Scaling up of High-Pressure Sliding (HPS) for Grain Refinement and Superplasticity

NASA Astrophysics Data System (ADS)

Takizawa, Yoichi; Masuda, Takahiro; Fujimitsu, Kazushige; Kajita, Takahiro; Watanabe, Kyohei; Yumoto, Manabu; Otagiri, Yoshiharu; Horita, Zenji

2016-09-01

The process of high-pressure sliding (HPS) is a method of severe plastic deformation developed recently for grain refinement of metallic materials under high pressure. The sample for HPS is used with a form of sheet or rod. In this study, an HPS facility with capacities of 500 tonnes for vertical pressing and of 500 and 300 tonnes for horizontal forward and backward pressings, respectively, was newly built and applied for grain refinement of a Mg alloy as AZ61, Al alloys such as Al-Mg-Sc, A2024 and A7075 alloys, a Ti alloy as ASTM-F1295, and a Ni-based superalloy as Inconel 718. Sheet samples with dimensions of 10 to 30 mm width, 100 mm length, and 1 mm thickness were processed at room temperature and ultrafine grains with sizes of ~200 to 300 nm were successfully produced in the alloys. Tensile testing at elevated temperatures confirmed the advent of superplasticity with total elongations of more than 400 pct in all the alloys. It is demonstrated that the HPS can make all the alloys superplastic through processing at room temperature with a form of rectangular sheets.

Damage Mechanisms and Mechanical Properties of High-Strength Multiphase Steels.

PubMed

Heibel, Sebastian; Dettinger, Thomas; Nester, Winfried; Clausmeyer, Till; Tekkaya, A Erman

2018-05-09

The usage of high-strength steels for structural components and reinforcement parts is inevitable for modern car-body manufacture in reaching lightweight design as well as increasing passive safety. Depending on their microstructure these steels show differing damage mechanisms and various mechanical properties which cannot be classified comprehensively via classical uniaxial tensile testing. In this research, damage initiation, evolution and final material failure are characterized for commercially produced complex-phase (CP) and dual-phase (DP) steels in a strength range between 600 and 1000 MPa. Based on these investigations CP steels with their homogeneous microstructure are characterized as damage tolerant and hence less edge-crack sensitive than DP steels. As final fracture occurs after a combination of ductile damage evolution and local shear band localization in ferrite grains at a characteristic thickness strain, this strain measure is introduced as a new parameter for local formability. In terms of global formability DP steels display advantages because of their microstructural composition of soft ferrite matrix including hard martensite particles. Combining true uniform elongation as a measure for global formability with the true thickness strain at fracture for local formability the mechanical material response can be assessed on basis of uniaxial tensile testing incorporating all microstructural characteristics on a macroscopic scale. Based on these findings a new classification scheme for the recently developed high-strength multiphase steels with significantly better formability resulting of complex underlying microstructures is introduced. The scheme overcomes the steel designations using microstructural concepts, which provide no information about design and production properties.

A measure of plastic anisotropy for hexagonal close packed metals: Application to alloying effects on the formability of Mg

DOE Office of Scientific and Technical Information (OSTI.GOV)

Arul Kumar, Mariyappan; Beyerlein, Irene Jane; Tome, Carlos N.

Mg is inherently plastically anisotropic and, over the years, alloying development efforts have sought to reduce the plastic anisotropy in order to enhance formability. To understand the relationship between alloy type and plastic anisotropy, we use a visco-plastic self-consistent (VPSC) polycrystal plasticity model to relate the macroscopic constitutive response to the underlying slip and twinning mechanisms in pure Mg and several Mg alloys. In the calculations, the influence of alloy type is represented by the differences in the CRSS values among the basal, prismatic, pyramidal slip and tensile twin systems. We show that for the same initial texture, this microscopic-levelmore » CRSS anisotropy can have a significant effect on the macroscopic indicators of formability, namely the anisotropy of the post-deformation polycrystal yield surface, tension-compression yield asymmetry, and Lankford coefficients. A plastic anisotropy (PA) measure is formulated to quantify the degree of single crystal plastic anisotropy acquired by the dissimilarities in the CRSS values of the slip and twinning modes for a given alloy. We demonstrate a strong correlation between the PA measure with the formability indicators mentioned above for multiple initial textures commonly enountered in processing. In conclusion, we find that alloys can be classified into two groups, those with a PA value below 2, which are more formable, less twinnable, and less sensitive to initial texture, where PA ~2 for pure Mg, and those with a PA value above 2, which possess the opposite deformation response.« less

Damage Mechanisms and Mechanical Properties of High-Strength Multiphase Steels

PubMed Central

Heibel, Sebastian; Dettinger, Thomas; Nester, Winfried; Tekkaya, A. Erman

2018-01-01

The usage of high-strength steels for structural components and reinforcement parts is inevitable for modern car-body manufacture in reaching lightweight design as well as increasing passive safety. Depending on their microstructure these steels show differing damage mechanisms and various mechanical properties which cannot be classified comprehensively via classical uniaxial tensile testing. In this research, damage initiation, evolution and final material failure are characterized for commercially produced complex-phase (CP) and dual-phase (DP) steels in a strength range between 600 and 1000 MPa. Based on these investigations CP steels with their homogeneous microstructure are characterized as damage tolerant and hence less edge-crack sensitive than DP steels. As final fracture occurs after a combination of ductile damage evolution and local shear band localization in ferrite grains at a characteristic thickness strain, this strain measure is introduced as a new parameter for local formability. In terms of global formability DP steels display advantages because of their microstructural composition of soft ferrite matrix including hard martensite particles. Combining true uniform elongation as a measure for global formability with the true thickness strain at fracture for local formability the mechanical material response can be assessed on basis of uniaxial tensile testing incorporating all microstructural characteristics on a macroscopic scale. Based on these findings a new classification scheme for the recently developed high-strength multiphase steels with significantly better formability resulting of complex underlying microstructures is introduced. The scheme overcomes the steel designations using microstructural concepts, which provide no information about design and production properties. PMID:29747417

Application Of A New Semi-Empirical Model For Forming Limit Prediction Of Sheet Material Including Superposed Loads Of Bending And Shearing

NASA Astrophysics Data System (ADS)

Held, Christian; Liewald, Mathias; Schleich, Ralf; Sindel, Manfred

2010-06-01

The use of lightweight materials offers substantial strength and weight advantages in car body design. Unfortunately such kinds of sheet material are more susceptible to wrinkling, spring back and fracture during press shop operations. For characterization of capability of sheet material dedicated to deep drawing processes in the automotive industry, mainly Forming Limit Diagrams (FLD) are used. However, new investigations at the Institute for Metal Forming Technology have shown that High Strength Steel Sheet Material and Aluminum Alloys show increased formability in case of bending loads are superposed to stretching loads. Likewise, by superposing shearing on in plane uniaxial or biaxial tension formability changes because of materials crystallographic texture. Such mixed stress and strain conditions including bending and shearing effects can occur in deep-drawing processes of complex car body parts as well as subsequent forming operations like flanging. But changes in formability cannot be described by using the conventional FLC. Hence, for purpose of improvement of failure prediction in numerical simulation codes significant failure criteria for these strain conditions are missing. Considering such aspects in defining suitable failure criteria which is easy to implement into FEA a new semi-empirical model has been developed considering the effect of bending and shearing in sheet metals formability. This failure criterion consists of the combination of the so called cFLC (combined Forming Limit Curve), which considers superposed bending load conditions and the SFLC (Shear Forming Limit Curve), which again includes the effect of shearing on sheet metal's formability.

A measure of plastic anisotropy for hexagonal close packed metals: Application to alloying effects on the formability of Mg

DOE PAGES

Arul Kumar, Mariyappan; Beyerlein, Irene Jane; Tome, Carlos N.

2016-11-01

Mg is inherently plastically anisotropic and, over the years, alloying development efforts have sought to reduce the plastic anisotropy in order to enhance formability. To understand the relationship between alloy type and plastic anisotropy, we use a visco-plastic self-consistent (VPSC) polycrystal plasticity model to relate the macroscopic constitutive response to the underlying slip and twinning mechanisms in pure Mg and several Mg alloys. In the calculations, the influence of alloy type is represented by the differences in the CRSS values among the basal, prismatic, pyramidal slip and tensile twin systems. We show that for the same initial texture, this microscopic-levelmore » CRSS anisotropy can have a significant effect on the macroscopic indicators of formability, namely the anisotropy of the post-deformation polycrystal yield surface, tension-compression yield asymmetry, and Lankford coefficients. A plastic anisotropy (PA) measure is formulated to quantify the degree of single crystal plastic anisotropy acquired by the dissimilarities in the CRSS values of the slip and twinning modes for a given alloy. We demonstrate a strong correlation between the PA measure with the formability indicators mentioned above for multiple initial textures commonly enountered in processing. In conclusion, we find that alloys can be classified into two groups, those with a PA value below 2, which are more formable, less twinnable, and less sensitive to initial texture, where PA ~2 for pure Mg, and those with a PA value above 2, which possess the opposite deformation response.« less

Multilevel model of polycrystalline materials: grain boundary sliding description

NASA Astrophysics Data System (ADS)

Sharifullina, E.; Shveykin, A.; Trusov, P.

2017-12-01

Material behavior description in a wide range of thermomechanical effects is one of the topical areas in mathematical modeling. Inclusion of grain boundary sliding as an important mechanism of polycrystalline material deformation at elevated temperatures and predominant deformation mechanism of metals and alloys in structural superplasticity allows to simulate various deformation regimes and their transitions (including superplasticity regime with switch-on and switch-off regimes). The paper is devoted to description of grain boundary sliding in structure of two-level model, based on crystal plasticity, and relations for determination the contribution of this mechanism to inelastic deformation. Some results are presented concerning computational experiments of polycrystalline representative volume deformation using developed model.

Formability and thermal stability of phase in (Fe1-y Coy)-(B, C, N) films

NASA Astrophysics Data System (ADS)

Sunaga, K.; Kadowaki, S.; Tsunoda, M.; Takahashi, M.

2004-06-01

In order to find a way to obtain stable -Fe16X2 phase, the formability and thermal stability of (bct) phase were discussed. According to a rigid sphere model, we concluded that the less formability of B for the phase is due to its large atomic radius. We elucidated the difference of thermal stability of -Fe-X, taking into account their decomposition process. While, the decomposition of -Fe-N progresses only by the migration of N, without changing the bone structure of Fe lattice, the additional energy is needed to break the original α-Fe lattice in the cases of α-Fe-B and α-Fe-C. Therefore thermal stability of α-Fe-B and α-Fe-C is higher than that of α-Fe-N.

Formability of Annealed Ni-Ti Shape Memory Alloy Sheet

NASA Astrophysics Data System (ADS)

Fann, K. J.; Su, J. Y.; Chang, C. H.

2018-03-01

Ni-Ti shape memory alloy has two specific properties, superelasiticity and shape memory effect, and thus is widely applied in diverse industries. To extend its application, this study attempts to investigate the strength and cold formability of its sheet blank, which is annealed at various temperatures, by hardness test and by Erichsen-like cupping test. As a result, the higher the annealing temperature, the lower the hardness, the lower the maximum punch load as the sheet blank fractured, and the lower the Erichsen-like index or the lower the formability. In general, the Ni-Ti sheet after annealing has an Erichsen-like index between 8 mm and 9 mm. This study has also confirmed via DSC that the Ni-Ti shape memory alloy possesses the austenitic phase and shows the superelasticity at room temperature.

Cold formability prediction by the modified maximum force criterion with a non-associated Hill48 model accounting for anisotropic hardening

NASA Astrophysics Data System (ADS)

Lian, J.; Ahn, D. C.; Chae, D. C.; Münstermann, S.; Bleck, W.

2016-08-01

Experimental and numerical investigations on the characterisation and prediction of cold formability of a ferritic steel sheet are performed in this study. Tensile tests and Nakajima tests were performed for the plasticity characterisation and the forming limit diagram determination. In the numerical prediction, the modified maximum force criterion is selected as the localisation criterion. For the plasticity model, a non-associated formulation of the Hill48 model is employed. With the non-associated flow rule, the model can result in a similar predictive capability of stress and r-value directionality to the advanced non-quadratic associated models. To accurately characterise the anisotropy evolution during hardening, the anisotropic hardening is also calibrated and implemented into the model for the prediction of the formability.

Superplastic forming and diffusion bonding of rapidly solidified, dispersion strengthened aluminum alloys for elevated temperature structural applications

NASA Technical Reports Server (NTRS)

Ting, E. Y.; Kennedy, J. R.

1989-01-01

Rapidly solidified alloys, based upon the Al-Fe-V-Si system and designed for elevated temperature applications, were evaluated for superplasticity and diffusion bonding behavior. Alloys with 8, 16, 27, and 36 volume percent silicide dispersoids were produced; dispersoid condition was varied by rolling at 300, 400, and 500 C (572, 752, and 932 F). Superplastic behavior was evaluated at strain rates from 1 x 10(exp -6)/s to 8.5/s at elevated temperatures. The results indicate that there was a significant increase in elongation at higher strain rates and at temperatures above 600 C (1112 F). However, the exposure of the alloys to temperatures greater than 600 C (1112 F) resulted in the coarsening of the strengthening dispersoid and the degradation of mechanical properties. Diffusion bonding was possible using low gas pressure at temperatures greater than 600 C (1112 F) which also resulted in degraded properties. The bonding of Al-Fe-V-Si alloys to 7475 aluminum alloy was performed at 516 C (960 F) without significant degradation in microstructure. Bond strengths equal to 90 percent that of the base metal shear strength were achieved. The mechanical properties and microstructural characteristics of the alloys were investigated.

Flow behaviour of magnesium alloy AZ31B processed by equal-channel angular pressing

NASA Astrophysics Data System (ADS)

Arun, M. S.; Chakkingal, U.

2014-08-01

Magnesium alloys are characterised by their low density, high specific strength and stiffness. But, the potential application of Mg is limited by its low room-temperature ductility & formability. Formability can be improved by developing an ultrafine grained (UFG) structure. Equal channel angular pressing (ECAP) is a well known process that can be used to develop an ultrafine grained microstructure. The aim of this study was to investigate the flow behaviour of AZ31B magnesium alloy after ECAP. The specimen was subjected to three passes of ECAP with a die angle of 120° using processing route Bc. The processing temperature was 523 K for the first pass and 423 K for the subsequent two passes. The microstructure characterisation was done. Compression tests of ECAPed and annealed specimens were carried out at strain rates of 0.01 - 1s-1 and deformation temperatures of 200 - 300°C using computer servo-controlled Gleeble-3800 system. The value of activation energy Q and the empirical materials constants of A and n were determined. The equations relating flow stress and Zener-Hollomon parameter were proposed. In the case annealed AZ31, the activation energy was determined to be 154 kJ/mol, which was slightly higher than the activation energy of 144 kJ/mol for ECAPed AZ31.

Formability behavior studies on CP-Al sheets processed through the helical tool path of incremental forming process

NASA Astrophysics Data System (ADS)

Markanday, H.; Nagarajan, D.

2018-02-01

Incremental sheet forming (ISF) is a novel die-less sheet metal forming process, which can produce components directly from the CAD geometry using a CNC milling machine at less production time and cost. The formability of the sheet material used is greatly affected by the process parameters involved and tool path adopted, and the present study is aimed to investigate the influence of different process parameter values using the helical tool path strategy on the formability of a commercial pure Al and to achieve maximum formability in the material. ISF experiments for producing an 80 mm diameter axisymmetric dome were carried out on 2 mm thickness commercially pure Al sheets for different tool speeds and feed rates in a CNC milling machine with a 10 mm hemispherical forming tool. The obtained parts were analyzed for springback, amount of thinning and maximum forming depth. The results showed that when the tool speed was increased by keeping the feed rate constant, the forming depth and thinning were also increased. On contrary, when the feed rate was increased by keeping the tool speed constant, the forming depth and thinning were decreased. Springback was found to be higher when the feed rate was increased rather than the tool speed was increased.

Microstructure, mechanical properties and stretch formability of Mg-3Al-0.5Ca-0.2Gd alloy processed at various finish rolling temperatures

NASA Astrophysics Data System (ADS)

Kang, Qiang; Jiang, Haitao; Zhang, Yun

2018-04-01

Effects of various finish rolling temperatures on the microstructure, texture, mechanical properties and stretch formability of rolled and annealed Mg-3Al-0.5Ca-0.2Gd (wt%) alloy were investigated in this paper, and it was found that compared with grain size and second phase particles, the basal textures, tensile properties and stretch formability Mg-3Al-0.5Ca-0.2Gd alloy are more sensitive to the increasing finishing rolling temperature. For the rolled and annealed Mg-3Al-0.5Ca-0.2Gd alloy, their grains barely grow up and second phase particles are slightly coarsened, while their basal poles are obviously weakened and tilted with increasing finish rolling temperature. Consequently, the weakened and RD-tilted basal textures are beneficial to the gradually improved elongation and stretch formability of Mg-3Al-0.5Ca-0.2Gd alloy. It is investigated that the gradually activated non-basal slips, e. g. 〈c 〉, 〈c + a〉 dislocations due to the increasing finish rolling temperature could contribute to the weakened RD-tilted textures in rolled and annealed Mg-3Al-0.5Ca-0.2Gd alloy.

Polyimide Aerogel Thin Films

NASA Technical Reports Server (NTRS)

Meador, Mary Ann; Guo, Haiquan

2012-01-01

Polyimide aerogels have been crosslinked through multifunctional amines. This invention builds on "Polyimide Aerogels With Three-Dimensional Cross-Linked Structure," and may be considered as a continuation of that invention, which results in a polyimide aerogel with a flexible, formable form. Gels formed from polyamic acid solutions, end-capped with anhydrides, and cross-linked with the multifunctional amines, are chemically imidized and dried using supercritical CO2 extraction to give aerogels having density around 0.1 to 0.3 g/cubic cm. The aerogels are 80 to 95% porous, and have high surface areas (200 to 600 sq m/g) and low thermal conductivity (as low as 14 mW/m-K at room temperature). Notably, the cross-linked polyimide aerogels have higher modulus than polymer-reinforced silica aerogels of similar density, and can be fabricated as both monoliths and thin films.

Analysis of Plastic Flow Instability During Superplastic Deformation of the Zn-Al Eutectoid Alloy Modified with 2 wt.% Cu

NASA Astrophysics Data System (ADS)

Ramos-Azpeitia, Mitsuo; Elizabeth Martínez-Flores, E.; Hernandez-Rivera, Jose Luis; Torres-Villaseñor, Gabriel

2017-11-01

The aim of this work is to analyze the plastic flow instability in Zn-21Al-2Cu alloy deformed under 10-3 s-1 and 513 K, which are optimum conditions for inducing superplastic behavior in this alloy. An evaluation using the Hart and Wilkinson-Caceres criteria showed that the limited stability of plastic flow observed in this alloy is related to low values of the strain-rate sensitivity index ( m) and the strain-hardening coefficient ( γ), combined with the tendency of these parameters to decrease depending on true strain ( ɛ). The reduction in m and γ values could be associated with the early onset of plastic instability and with microstructural changes observed as function of the strain. Grain growth induced by deformation seems to be important during the first stage of deformation of this alloy. However, when ɛ > 0.4 this growth is accompanied by other microstructural rearrangements. These results suggest that in this alloy, a grain boundary sliding mechanism acts to allow a steady superplastic flow only for ɛ < 0.4. For ɛ values between 0.4 and 0.7, observed occurrences of microstructural changes and severe neck formation lead to the supposition that there is a transition in the deformation mechanism. These changes are more evident when ɛ > 0.7 as another mechanism is thought to take over.

Experimental formability analysis of bondal sandwich sheet

NASA Astrophysics Data System (ADS)

Kami, Abdolvahed; Banabic, Dorel

2018-05-01

Metal/polymer/metal sandwich sheets have recently attracted the interests of industries like automotive industry. These sandwich sheets have superior properties over single-layer metallic sheets including good sound and vibration damping and light weight. However, the formability of these sandwich sheets should be enhanced which requires more research. In this paper, the formability of Bondal sheet (DC06/viscoelastic polymer/DC06 sandwich sheet) was studied through different types of experiments. The mechanical properties of Bondal were determined by uniaxial tensile tests. Hemispherical punch stretching and hydraulic bulge tests were carried out to determine the forming limit diagram (FLD) of Bondal. Furthermore, cylindrical and square cup drawing tests were performed in dry and oil lubricated conditions. These tests were conducted at different blank holding forces (BHFs). An interesting observation about Bondal sheet deep drawing was obtaining of higher drawing depths at dry condition in comparison with oil-lubricated condition.

Effect of Geometric Parameters on Formability and Strain Path During Tube Hydrforming Process

NASA Astrophysics Data System (ADS)

Omar, A.; Harisankar, K. R.; Tewari, Asim; Narasimhan, K.

2016-08-01

Forming limit diagram (FLD) is an important tool to measure the material's formability for metal forming processes. In order to successfully manufacture a component through tube hydroforming process it is very important to know the effect of material properties, process and geometrical parameters on the outcome of finished product. This can be obtained by running a finite element code which not only saves time and money but also gives a result with considerable accuracy. Therefore, in this paper the mutual effect of diameter as well as thickness has been studied. Firstly the finite element based prediction is carried out to assess the formability of seamless and welded tubes with varying thickness. Later on, effect of varying diameter and thickness on strain path is predicted using statistical based regression analysis. Finally, the mutual effect of varying material property alongwith varying thickness and diameter on constraint factor is studied.

Investigation of the Formability of TRIP780 Steel Sheets

NASA Astrophysics Data System (ADS)

Song, Yang

The formability of a metal sheet is dependent on its work hardening behaviour and its forming limits; and both aspects must be carefully determined in order to accurately simulate a particular forming process. This research aims to characterize the formability of a TRIP780 sheet steel using advanced experimental testing and analysis techniques. A series of flat rolling and tensile tests, as well as shear tests were conducted to determine the large deformation work hardening behaviour of this TRIP780 steel. Nakazima tests were carried out up to fracture to determine the forming limits of this sheet material. A highly-automated method for generating a robust FLC for sheet materials from DIC strain measurements was created with the help of finite element simulations, and evaluated against the conventional method. A correction algorithm that aims to compensate for the process dependent effects in the Nakazima test was implemented and tested with some success.

TUNGSTEN BASE ALLOYS

DOEpatents

Schell, D.H.; Sheinberg, H.

1959-12-15

A high-density quaternary tungsten-base alloy having high mechanical strength and good machinability composed of about 2 wt.% Ni, 3 wt.% Cu, 5 wt.% Pb, and 90wt.% W is described. This alloy can be formed by the powder metallurgy technique of hot pressing in a graphite die without causing a reaction between charge and the die and without formation of a carbide case on the final compact, thereby enabling re-use of the graphite die. The alloy is formable at hot- pressing temperatures of from about 1200 to about 1350 deg C. In addition, there is little component shrinkage, thereby eliminating the necessity of subsequent extensive surface machining.

HBCU/MI: 3D Formable RF Materials and Devices

DTIC Science & Technology

2016-08-01

SECURITY CLASSIFICATION OF: The aim of this project was to explore 3D printing for RF/microwave circuits and devices. The research produced several... 3D printed microwave filters, a 3D wifi radio circuit, and new materials for 3D printed electromagnetic devices. The research demonstrates that 3D ...journals: Final Report: HBCU/MI: 3D Formable RF Materials and Devices Report Title The aim of this project was to explore 3D printing for RF/microwave

Superconducting MgB2 wires with vanadium diffusion barrier

NASA Astrophysics Data System (ADS)

Hušek, I.; Kováč, P.; Melišek, T.; Kulich, M.; Rosová, A.; Kopera, L.; Szundiová, B.

2017-10-01

Single-core MgB2 wires with a vanadium barrier and Cu stabilization have been made by the in situ powder-in-tube (PIT) and internal magnesium diffusion (IMD) into boron processes. Heat treatment of PIT wires was done at the temperature range of 650 °C-850 °C/30 min. Critical currents of differently treated MgB2/V/Cu wires have been measured and related with the structure of MgB2. It was found that critical current density of MgB2/V wire annealed above 700 °C decreases rapidly. The obtained results clearly show that vanadium is a well formable metal and can be applied as an effective diffusion barrier for MgB2 wires heat-treated at temperatures ≤700 °C. This temperature limit is well applicable for MgB2 wires with high current densities made by PIT and also by the IMD process.

Rock mechanics. Superplastic nanofibrous slip zones control seismogenic fault friction.

PubMed

Verberne, Berend A; Plümper, Oliver; de Winter, D A Matthijs; Spiers, Christopher J

2014-12-12

Understanding the internal mechanisms controlling fault friction is crucial for understanding seismogenic slip on active faults. Displacement in such fault zones is frequently localized on highly reflective (mirrorlike) slip surfaces, coated with thin films of nanogranular fault rock. We show that mirror-slip surfaces developed in experimentally simulated calcite faults consist of aligned nanogranular chains or fibers that are ductile at room conditions. These microstructures and associated frictional data suggest a fault-slip mechanism resembling classical Ashby-Verrall superplasticity, capable of producing unstable fault slip. Diffusive mass transfer in nanocrystalline calcite gouge is shown to be fast enough for this mechanism to control seismogenesis in limestone terrains. With nanogranular fault surfaces becoming increasingly recognized in crustal faults, the proposed mechanism may be generally relevant to crustal seismogenesis. Copyright © 2014, American Association for the Advancement of Science.

Process Simulation of Aluminium Sheet Metal Deep Drawing at Elevated Temperatures

DOE Office of Scientific and Technical Information (OSTI.GOV)

Winklhofer, Johannes; Trattnig, Gernot; Lind, Christoph

Lightweight design is essential for an economic and environmentally friendly vehicle. Aluminium sheet metal is well known for its ability to improve the strength to weight ratio of lightweight structures. One disadvantage of aluminium is that it is less formable than steel. Therefore complex part geometries can only be realized by expensive multi-step production processes. One method for overcoming this disadvantage is deep drawing at elevated temperatures. In this way the formability of aluminium sheet metal can be improved significantly, and the number of necessary production steps can thereby be reduced. This paper introduces deep drawing of aluminium sheet metalmore » at elevated temperatures, a corresponding simulation method, a characteristic process and its optimization. The temperature and strain rate dependent material properties of a 5xxx series alloy and their modelling are discussed. A three dimensional thermomechanically coupled finite element deep drawing simulation model and its validation are presented. Based on the validated simulation model an optimised process strategy regarding formability, time and cost is introduced.« less

Stamp forming optimization for formability and crystallinity

NASA Astrophysics Data System (ADS)

Donderwinkel, T. G.; Rietman, B.; Haanappel, S. P.; Akkerman, R.

2016-10-01

The stamp forming process is well suited for high volume production of thermoplastic composite parts. The process can be characterized as highly non-isothermal as it involves local quench-cooling of a molten thermoplastic composite blank where it makes contact with colder tooling. The formability of the thermoplastic composite depends on the viscoelastic material behavior of the matrix material, which is sensitive to temperature and degree of crystallinity. An experimental study was performed to determine the effect of temperature and crystallinity on the storage modulus during cooling for a woven glass fiber polyamide-6 composite material. An increase of two decades in modulus was observed during crystallization. As this will significantly impede the blank formability, the onset of crystallization effectively governs the time available for forming. Besides the experimental work, a numerical model is developed to study the temperature and crystallinity throughout the stamp forming process. A process window can be determined by feeding the model with the experimentally obtained data on crystallization.

Process Parameters Optimization in Single Point Incremental Forming

NASA Astrophysics Data System (ADS)

Gulati, Vishal; Aryal, Ashmin; Katyal, Puneet; Goswami, Amitesh

2016-04-01

This work aims to optimize the formability and surface roughness of parts formed by the single-point incremental forming process for an Aluminium-6063 alloy. The tests are based on Taguchi's L18 orthogonal array selected on the basis of DOF. The tests have been carried out on vertical machining center (DMC70V); using CAD/CAM software (SolidWorks V5/MasterCAM). Two levels of tool radius, three levels of sheet thickness, step size, tool rotational speed, feed rate and lubrication have been considered as the input process parameters. Wall angle and surface roughness have been considered process responses. The influential process parameters for the formability and surface roughness have been identified with the help of statistical tool (response table, main effect plot and ANOVA). The parameter that has the utmost influence on formability and surface roughness is lubrication. In the case of formability, lubrication followed by the tool rotational speed, feed rate, sheet thickness, step size and tool radius have the influence in descending order. Whereas in surface roughness, lubrication followed by feed rate, step size, tool radius, sheet thickness and tool rotational speed have the influence in descending order. The predicted optimal values for the wall angle and surface roughness are found to be 88.29° and 1.03225 µm. The confirmation experiments were conducted thrice and the value of wall angle and surface roughness were found to be 85.76° and 1.15 µm respectively.

Optimum Combination of Thermoplastic Formability and Electrical Conductivity in Al-Ni-Y Metallic Glass

NASA Astrophysics Data System (ADS)

Na, Min Young; Park, Sung Hyun; Kim, Kang Cheol; Kim, Won Tae; Kim, Do Hyang

2018-05-01

Both thermoplastic formability and electrical conductivity of Al-Ni-Y metallic glass with 12 different compositions have been investigated in the present study with an aim to apply as a functional material, i.e. as a binder of Ag powders in Ag paste for silicon solar cell. The thermoplastic formability is basically influenced by thermal stability and fragility of supercooled liquid which can be reflected by the temperature range for the supercooled liquid region (ΔT x ) and the difference in specific heat between the frozen glass state and the supercooled liquid state (ΔC p ). The measured ΔT x and ΔC p values show a strong composition dependence. However, the composition showing the highest ΔT x and ΔC p does not correspond to the composition with the highest amount of Ni and Y. It is considered that higher ΔT x and ΔC p may be related to enhancement of icosahedral SRO near T g during cooling. On the other hand, electrical resistivity varies with the change of Al contents as well as with the change of the volume fraction of each phase after crystallization. The composition range with the optimum combination of thermoplastic formability and electrical conductivity in Al-Ni-Y system located inside the composition triangle whose vertices compositions are Al87Ni3Y10, Al85Ni5Y10, and Al86Ni5Y9.

Simulation Study on Jet Formability and Damage Characteristics of a Low-Density Material Liner

PubMed Central

Tang, Wenhui; Ran, Xianwen

2018-01-01

The shaped charge tandem warhead is an effective weapon against the ERA (explosive reactive armor). Whether the pre-warhead can reliably initiate the ERA directly determines the entire performance of the tandem warhead. The existing shaped charge pre-warhead mostly adopts a metal shaped jet, which effectively initiates the ERA, but interferes the main shaped jet. This article, on the other hand, explores the possibility of producing a pre-warhead using a low-density material as the liner. The nonlinear dynamic analysis software Autodyn-2D is used to simulate and compare three kinds of low-density shaped jets, including floatglass, Lucite, and Plexiglas, to the copper shaped jet in the effectiveness of impacting ERA. Based on the integrative criteria (including u-d initiation criterion, explosive reactive degree, explosive pressure, and particle velocity of the panels), it can be determined whether the low-density shaped jet can reliably initiate the sandwich charge. The results show that the three kinds of low-density shaped jets can not only initiate the reaction armor, but are also superior to the existing copper shaped jet in ductility, jet tip velocity, jet tip diameter, and the mass; namely, it is feasible to use the low-density material shaped jet to destroy the ERA. PMID:29300351

Effect of temperature and grain size on the dominant diffusion process for superplastic flow in an AZ61 magnesium alloy

DOE Office of Scientific and Technical Information (OSTI.GOV)

Watanabe, H.; Mukai, T.; Kohzu, M.

1999-10-26

The effect of temperature and grain size on superplastic flow was investigated using a relatively coarse-grained ({approximately}20 {micro}m) Mg-Al-Zn alloy for the inclusive understanding of the dominant diffusion process. Tensile tests revealed that the strain rate was inversely proportional to the square of the grain size and to the second power of stress. The activation energy was close to that for grain boundary diffusion at 523--573 K, and was close to that for lattice diffusion at 598--673 K. From the analysis of the stress exponent, the grain size exponent and activation energy, it was suggested that the dominant diffusion processmore » was influenced by temperature and grain size. It was demonstrated that the notion of effective diffusivity explained the experimental results.« less

Application of superplastically formed and diffusion bonded aluminum to a laminar flow control leading edge

NASA Technical Reports Server (NTRS)

Goodyear, M. D.

1987-01-01

NASA sponsored the Aircraft Energy Efficiency (ACEE) program in 1976 to develop technologies to improve fuel efficiency. Laminar flow control was one such technology. Two approaches for achieving laminar flow were designed and manufactured under NASA sponsored programs: the perforated skin concept used at McDonnell Douglas and the slotted design used at Lockheed-Georgia. Both achieved laminar flow, with the slotted design to a lesser degree (JetStar flight test program). The latter design had several fabrication problems concerning springback and adhesive flow clogging the air flow passages. The Lockheed-Georgia Company accomplishments is documented in designing and fabricating a small section of a leading edge article addressing a simpler fabrication method to overcome the previous program's manufacturing problems, i.e., design and fabrication using advanced technologies such as diffusion bonding of aluminum, which has not been used on aerospace structures to date, and the superplastic forming of aluminum.

Elevated-temperature flow strength, creep resistance and diffusion welding characteristics of Ti-gAl-2Nb-1Ta-0.8Mo

NASA Technical Reports Server (NTRS)

Whittenberger, J. D.; Moore, T. J.

1977-01-01

A study of the flow strength, creep resistance and diffusion welding characteristics of the titanium alloy Ti-6Al-2Nb-1Ta-0.8Mo was conducted. Two mill-processed forms of this alloy were examined. The forged material was essentially processed above the beta transus while the rolled form was subjected to considerable work below the beta transus. Between 1150 and 1250 K, the forged material was stronger and more creep resistant than the rolled alloy. Both forms exhibit superplastic characteristics in this temperature range. Strain measurements during diffusion welding experiments at 1200 K reveal that weld interfaces have no measurable effect on the overall creep deformation. Significant deformation appears to be necessary to produce a quality diffusion weld between superplastic materials. A 'soft' interlayer inserted between faying surfaces would seemingly allow manufacture of quality diffusion welds with little overall deformation.

Texture evolution during low temperature superplasticity in 5083 and 5052 Al-Mg alloys

DOE Office of Scientific and Technical Information (OSTI.GOV)

Su, S.W.; Hsiao, I.C.; Huang, J.C.

2000-07-01

Low temperature superplasticity (LTSP) at 250 C and 1 x 10{sup {minus}3} s{sup {minus}1} was observed in the 5083 Al-Mg base alloy after thermomechanical treatments (TMT). With increasing TMT rolling strain, the high angle grain boundary fraction increased, more favorable for the further operation of grain boundary sliding and LTSP. The strong texture components and bimodal misorientation distributions present after TMT were not affected by static annealing at 250 C, but evolved gradually into a random orientation distribution during LTSP straining from 30% to 100%. When the LTSP elongation was greater than 150%, the macro-deformation anisotropy R ratio would finallymore » reach a stable level. It seems that the LTSP performance was controlled by a large fraction of high angle boundaries, but not by the special coincidence site lattice boundaries.« less

SPITFIRE-1

NASA Technical Reports Server (NTRS)

Ryntz, Edward F.

1995-01-01

The purpose of this effort is to develop low-cost rapid forming superplastic aluminum that will be evaluated in pilot production trials for automotive SPF components. The alloy development study conducted under SPITFIRE-1 showed that the addition of CU or Mn to the base 5083 aluminum alloy refined the grain size, leading to enhanced superplastic properties. In SPITFIRE-2, these alloy variants will be further refined and studied to meet the target properties established earlier in the program. Mechanical properties, component forming and post-forming properties will be evaluated. Also, the alloy production process, including thermomechanical processing (TMP) optimization to reduce production cost, will be investigated during SPITFIRE-2. After identifying preferred compositions and production processing, the most promising alloy will be manufactured into production coils for verification during SPITFIRE-3. Components will be produced from these coils in SPITFIRE-4, and the process and component performance will be assessed.

Ti6Al4V Superplastic Forming for the Production of an Aircraft Part

NASA Astrophysics Data System (ADS)

Filice, L.; Gagliardi, F.; Lazzaro, S.; Rosa, R.

2011-05-01

Titanium and its alloys have grown their importance in the automotive and aerospace industries becoming strategic materials; this is due to their mechanical properties that, perfectly, meet the needs of the above said industrial field. For example, they are characterized by a high strength vs. weight ratio that is directly related to fuel saving impacting on both economic and environmental aspects. A weakness point of these materials is linked to their workability that entails significant manufacturing costs. Taking into account these issues, it is easy to understand the reasons for the development of net shape technologies, like hot forming (HF) or superplastic forming (SPF) in order to reduce the price of titanium components. In the work here introduced, a cockpit section, known as "Pocket Support", was produced through SPF. More in detail, the influence that the strain rate can have on the quality of the final part was highlighted; for this reason, two different pressure-time curves were tested monitoring the accuracy and wall thinning of the realized parts. The experimental campaign was carried out using an ACB superplastic forming press located in the Somma Vesuviana DEMA plant. The dimension of the obtained components were checked through the structural light technique (Gray Code-Phase Shifting); in particular, a cloud of points was obtained and, subsequently, used to rebuild the actual surface of the Pocket Support. In this way, a comparison between the CAD model and the real part was possible. Moreover, the thickness distribution along a critical section was analyzed by means of a coordinate measuring machine.

Effect of Hot Rolling Process on Microstructure and Properties of Low-Carbon Al-Killed Steels Produced Through TSCR Technology

NASA Astrophysics Data System (ADS)

Paul, S. K.; Ahmed, U.; Megahed, G. M.

2011-10-01

Low-carbon Al-killed hot rolled strips for direct forming, cold rolling, and galvanizing applications are produced from the similar chemistry at Ezz Flat Steel (EFS) through thin slab casting and rolling (TSCR) technology. The desired mechanical and microstructural properties in hot bands for different applications are achieved through control of hot rolling parameters, which in turn control the precipitation and growth of AlN. Nitrogen in solid solution strongly influences the yield strength (YS), ductility, strain aging index (SAI), and other formability properties of steel. The equilibrium solubility of AlN in austenite at different temperatures and its isothermal precipitation have been studied. To achieve the formability properties for direct forming, soluble nitrogen is fixed as AlN by coiling the strip at higher temperatures. For stringent cold forming, boron was added below the stoichiometric ratio with nitrogen, which improved the formability properties dramatically. The requirements of hot band for processing into cold rolled and annealed deep drawing sheets are high SAI and fine-grain microstructure. Higher finish rolling and low coiling temperatures are used to achieve these. Fully processed cold rolled sheets from these hot strips at customer's end have shown good formability properties. Coil break marks observed in some coils during uncoiling were found to be associated with yielding phenomenon. The spike height (difference between upper and lower yield stresses) and yield point elongation (YPE) were found to be the key material parameters for the break marks. Factors affecting these parameters have been studied and the coiling temperature optimized to overcome the problem.

AFWAL FY80 Technical Accomplishments Report.

DTIC Science & Technology

1981-12-01

through cooperative effort of the Materials and Certain compositions in the titanium aluminide Propulsion Laboratories. In addition to an extensive system...Bonded Structures Technology Transitioned .................................................. 43 Superplastically Formed and Diffusion Bonded Titanium ...Technology ................................................................................................. 75 First RSR Radial Wafer Blade Engine Test

Effect of Annealing on Mechanical Properties and Formability of Cold Rolled Thin Sheets of Fe-P P/M Alloys

NASA Astrophysics Data System (ADS)

Trivedi, Shefali; Ravi Kumar, D.; Aravindan, S.

2016-10-01

Phosphorus in steel is known to increase strength and hardness and decrease ductility. Higher phosphorus content (more than 0.05%), however, promotes brittle behavior due to segregation of Fe3P along the grain boundaries which makes further mechanical working of these alloys difficult. In this work, thin sheets of Fe-P alloys (with phosphorus in range of 0.1-0.35%) have been developed through processing by powder metallurgy followed by hot rolling and cold rolling. The effect of phosphorus content and annealing parameters (temperature and time) on microstructure, mechanical properties, formability in biaxial stretching and fracture behavior of the cold rolled and annealed sheets has been studied. A comparison has also been made between the properties of the sheets made through P/M route and the conventional cast route with similar phosphorus content. It has been shown that thin sheets of Fe-P alloys with phosphorous up to 0.35% possessing a good combination of strength and formability can be produced through rolling of billets of these alloys made through powder metallurgy technique without the problem of segregation.

Residual-stress-induced grain growth of twinned grains and its effect on formability of magnesium alloy sheet at room temperature

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kim, Se-Jong; Kim, Daeyong, E-mail: daeyong@kims.re.kr; Lee, Keunho

2015-11-15

A magnesium alloy sheet was subjected to in-plane compression along with a vertical load to avoid buckling during compression. Pre-compressed specimens machined from the sheet were annealed at different temperatures and the changes in microstructure and texture were observed using electron back scattered diffraction (EBSD). Twinned grains preferentially grew during annealing at 300 °C, so that a strong texture with the < 0001 > direction parallel to the transverse direction developed. EBSD analysis confirmed that the friction caused by the vertical load induced inhomogeneous distribution of residual stress, which acted as an additional driving force for preferential grain growth ofmore » twinned grain during annealing. The annealed specimen showed excellent formability. - Highlights: • A magnesium alloy sheet subjected to in-plane compression under a vertical load • The vertical load induced inhomogeneous distribution of the residual stress. • The residual stress acted as an additional driving force for grain growth. • The annealed specimen with strong non-basal texture showed excellent formability.« less

Applications of Computer Simulation Methods in Plastic Forming Technologies for Magnesium Alloys

NASA Astrophysics Data System (ADS)

Zhang, S. H.; Zheng, W. T.; Shang, Y. L.; Wu, X.; Palumbo, G.; Tricarico, L.

2007-05-01

Applications of computer simulation methods in plastic forming of magnesium alloy parts are discussed. As magnesium alloys possess very poor plastic formability at room temperature, various methods have been tried to improve the formability, for example, suitable rolling process and annealing procedures should be found to produce qualified magnesium alloy sheets, which have the reduced anisotropy and improved formability. The blank can be heated to a warm temperature or a hot temperature; a suitable temperature field is designed, tools should be heated or the punch should be cooled; suitable deformation speed should be found to ensure suitable strain rate range. Damage theory considering non-isothermal forming is established. Various modeling methods have been tried to consider above situations. The following situations for modeling the forming process of magnesium alloy sheets and tubes are dealt with: (1) modeling for predicting wrinkling and anisotropy of sheet warm forming; (2) damage theory used for predicting ruptures in sheet warm forming; (3) modeling for optimizing of blank shape and dimensions for sheet warm forming; (4) modeling in non-steady-state creep in hot metal gas forming of AZ31 tubes.

Reversed austenite for enhancing ductility of martensitic stainless steel

NASA Astrophysics Data System (ADS)

Dieck, S.; Rosemann, P.; Kromm, A.; Halle, T.

2017-03-01

The novel heat treatment concept, “quenching and partitioning” (Q&P) has been developed for high strength steels with enhanced formability. This heat treatment involves quenching of austenite to a temperature between martensite start and finish, to receive a several amount of retained austenite. During the subsequent annealing treatment, the so called partitioning, the retained austenite is stabilized due to carbon diffusion, which results in enhanced formability and strength regarding strain induced austenite to martensite transformation. In this study a Q&P heat treatment was applied to a Fe-0.45C-0.65Mn-0.34Si-13.95Cr stainless martensite. Thereby the initial quench end temperature and the partitioning time were varied to characterize their influence on microstructural evolution. The microstructural changes were analysed by dilatometer measurements, X-ray diffraction and scanning electron microscopy, including electron back-scatter diffraction. Compression testing was made to examine the mechanical behaviour. It was found that an increasing partitioning time up to 30 min leads to an enhanced formability without loss in strength due to a higher amount of stabilized retained and reversed austenite as well as precipitation hardening.

Method of Heat Treating Aluminum-Lithium Alloy to Improve Formability

NASA Technical Reports Server (NTRS)

Russell, Carolyn Kurgan (Inventor); Chen, Po-Shou (Inventor)

2016-01-01

A method is provided for heat treating aluminum-lithium alloys to improve their formability. The alloy is heated to a first temperature, maintained at the first temperature for a first time period, heated at the conclusion of the first time period to a second temperature, maintained at the second temperature for a second time period, actively cooled at the conclusion of the second time period to a third temperature, maintained at the third temperature for a third time period, and then passively cooled at the conclusion of the third time period to room temperature.

Effect of thermal treatment on the bio-corrosion and mechanical properties of ultrafine-grained ZK60 magnesium alloy.

PubMed

Choi, H Y; Kim, W J

2015-11-01

The combination of solid solution heat treatments and severe plastic deformation by high-ratio differential speed rolling (HRDSR) resulted in the formation of an ultrafine-grained microstructure with high thermal stability in a Mg-5Zn-0.5Zr (ZK60) alloy. When the precipitate particle distribution was uniform in the matrix, the internal stresses and dislocation density could be effectively removed without significant grain growth during the annealing treatment (after HRDSR), leading to enhancement of corrosion resistance. When the particle distribution was non-uniform, rapid grain growth occurred in local areas where the particle density was low during annealing, leading to development of a bimodal grain size distribution. The bimodal grain size distribution accelerated corrosion by forming a galvanic corrosion couple between the fine-grained and coarse-grained regions. The HRDSR-processed ZK60 alloy with high thermal stability exhibited high corrosion resistance, high strength and high ductility, and excellent superplasticity, which allow the fabrication of biodegradable magnesium devices with complicated designs that have a high mechanical integrity throughout the service life in the human body. Copyright © 2015 Elsevier Ltd. All rights reserved.

Experimental investigation of edge hardening and edge cracking sensitivity of burr-free parts

NASA Astrophysics Data System (ADS)

Senn, Sergei; Liewald, Mathias

2018-05-01

This experimental study is focused on characterisation of edge hardening of sheet metal and remaining formability of differently prepared cutted edges. Edge cracking sensitivity of counter cutted, shear cutted, recutted and water-jet cutted components are compared and evaluated. Subsequently, edge hardening and hole expansion ratio were correlated for material HC420 LA with sheet thickness of t = 2 mm. As other studies show, the cutting edge surface quality influences the hole expansion ratio: a high clear cut surface increases formability of cutting edges, whereas micro cracks and rough surfaces result into a large fracture surface, which impact remaining formability noticeably. Thus, cutting edges with lower edge hardening behaviour in conjunction with a higher clear cut surface exhibit higher hole expansion ratios. Counter cutting and the recutting do show a similar effect on edge hardening. Using the hole expansion test, it was possible to prove that counter cutted components show a significantly lower edge cracking sensitivity in comparison to conventionally shear cutted components. The hole expansion ratio of counter cutted specimens looks balanced and is comparable to the hole expansion ratio measured from specimens with recutted or water jet cutted edges. The significant difference of the investigated cutting processes is characterized by size of clear cutting area. This area of recutted edges emerges larger than the area of counter cutted specimens, which evidently leads to an increased hole expansion ratio of recutted specimens compared to conventionally shear cutted ones. However, it is important to note that the hole expansion ratio of counter cutted and recutted specimens appear fairly balanced, but counter cutted samples indeed can be produced burr-free. Using counter cutting technology, it is possible to produce burr free surfaces with high edge formability.

Improving Strength-Ductility Balance of High Strength Dual-Phase Steels by Addition of Vanadium

NASA Astrophysics Data System (ADS)

Gong, Yu; Hua, M.; Uusitalo, J.; DeArdo, A. J.

For galvanized or galvannealed steels to be commercially successful, they must exhibit several attributes: (i) easy and inexpensive processing in the hot mill, cold mill and on the coating line, (ii) high strength with good formability and spot weldability, and (iii) good corrosion resistance, especially after cold forming. For good corrosion resistance, the coating must have sufficient coverage, be of uniform thickness, and most importantly, the coating must survive the cold stamping or forming operation. The purpose of this paper is to present research aiming at improving the steel substrate, such that high strength can be obtained while maintaining good global formability (tensile ductility), local formability (sheared-edge ductility), and good spot weldability. It is well-known that the strength of DP steels is controlled by several factors, including the amount of martensite found in the final microstructure. Recent research has revealed that the amount of austenite formed during intercritical annealing can be strongly influenced by the annealing temperature and the pre-annealing conditions of the hot band (coiling temperature) and cold band (% cold reduction). Current experiments have explored the combination of pre-annealing conditions and four annealing practices to help define the best practice to optimize the strength-formability balance in these higher strength DP steels. The steels used in these experiments contained (i) low carbon content for good spot weldability, (ii) the hardenability additions Mo and Cr for strength, and (iii) V for grain refinement, precipitation hardening and temper resistance. When processed correctly, these steels exhibited UTS levels up to 1000MPa, total elongation to 25%, reduction in area to 45%, and Hole Expansion Ratios to 50%. The results of this program will be presented and discussed.

A novel approach to determine the thermal transition of gum powder/hydro-gels using dynamic mechanical analysis

NASA Astrophysics Data System (ADS)

Nagamadhu, M.; Jeyaraj, P.; Kumar, G. C. Mohan

2018-04-01

The dynamic characterization of materials plays a major role in the present area. The many researchers are worked on solid materials and its characterization, it can be tested using dynamic mechanical analyzer (DMA), however, no such work on powder a semiliquid samples. The powder and liquid samples can also easily characterization as like solid samples using DMA. These powder samples are analyzed with a material pocket method which can be used to accurately determine very low levels of variation in powder properties, due to the high sensitivity of DMA to glass transitions. No such DMA studies on hydrogel and Gum powders. The gum powders are used in various applications start from food industries, pharmacy, natural gums paste, biomedical applications etc. among all this applications gum Ghatti is one of the powders using for varies applications. Around 50 milligrams of Ghatti powders are placed inside material pocket and analyzed storage modulus (G'), loss modulus (G″) and tan delta (δ). Also, understand the curing and glass transition effect using water, glycerin and superplastic from room temperature to 200°C. The result shows that storage modulus decreases with increase in temperature in pure Ghatti powder. The surprising improvement in storage modulus was found with an increase in temperature with addition of water, glycerin, and superplastic. However, loss modulus and tan delta are also having very significant influence and also shows a clear peak of the tan delta. The loss modulus results were found to be improved by adding solidifying agents, along with this water and superplastic better influence. But glycerine found to be hydrogel in nature and thermodynamic properties are much influenced by frequency.

Deformation behaviour of a new magnesium ternary alloy

NASA Astrophysics Data System (ADS)

Guglielmi, P.; Kaya, A. Arslan; Sorgente, D.; Palumbo, G.

2018-05-01

Magnesium based alloys are yet to fill a greater niche especially in the automotive and aeronautical industry. In fact, such alloys have a big weight saving potential, together with good damping characteristics. However, nowadays about 90% of Magnesium products are produced by casting, mainly using two alloy systems, namely Mg-Al-Zn (AZ91D) and Mg-Al (AM50, AM60). Now the emphasis, especially after having achieved considerable success in creep resistance and understanding of the deformation behaviour of Magnesium, has been shifted towards wrought alloys; AZ31, in this case, is the most popular. In this work a multi-element Magnesium alloy, developed to improve the deformation capacity of such a lightweight material, has been investigated and compared to a commercial AZ31B. The possibility of adopting such a multi-element Magnesium alloy for manufacturing components via unconventional sheet forming (such as superplastic forming, warm hydroforming, incremental forming) has been proved in the present work focusing the attention on the superplastic field. Free inflation tests were thus conducted at 450°C setting constant pressure to investigate the superplastic behaviour (in terms of dome height and strain rate sensitivity index) of both the multi-element Magnesium alloy (Mg-2Zn-Ce) and the commercial one (AZ31B). To enhance information on the thickness distribution and investigate the microstructure evolution, metallographic analyses on the samples used to carry out free inflation tests were also performed. The developed ternary alloy manifested quite a good deformation behaviour (high strain rate sensitivity index), even being tested in the as cast condition; in addition a limited grain coarsening was observed in the specimens after deformation.

Elevated temperature flow strength, creep resistance and diffusion welding characteristics of Ti-6Al-2Nb-1Ta-0.8Mo

NASA Technical Reports Server (NTRS)

Whittenberger, J. D.; Moore, T. J.

1979-01-01

A study of the flow strength, creep resistance and diffusion welding characteristics of the titanium alloy Ti-6Al-2Nb-1Ta-0.8Mo has been conducted. Two mill-processed forms of this alloy were examined. The forged material had been processed above the beta transus (approximately 1275 K) while the rolled form had been subjected to work below the beta transus. Between 1150 and 1250 K, the forged material was stronger and more creep resistant than the rolled alloy. Both forms exhibit superplastic characteristics in this temperature range. Strain measurements during diffusion welding experiments at 1200 K reveal that weld interfaces have no measurable effect on the overall creep deformation. Significant deformation appears to be necessary to produce a quality diffusion weld between superplastic materials. A 'soft' interlayer inserted between faying surfaces would seemingly allow manufacture of quality diffusion welds with little overall deformation.

Evaluation of superplastic forming and co-diffusion bonding of Ti-6Al-4V titanium alloy expanded sandwich structures

NASA Technical Reports Server (NTRS)

Arvin, G. H.; Israeli, L.; Stolpestad, J. H.; Stacher, G. W.

1981-01-01

The application of the superplastic forming/diffusion bonding (SPF/DB) process to supersonic cruise research is investigated. The capability of an SPF/DB titanium structure to meet the structural requirements of the inner wing area of the NASA arrow-wing advanced supersonic transport design is evaluated. Selection of structural concepts and their optimization for minimum weight, SPF/DB process optimization, fabrication of representative specimens, and specimen testing and evaluation are described. The structural area used includes both upper and lower wing panels, where the upper wing panel is used for static compression strength evaluation and the lower panel, in tension, is used for fracture mechanics evaluations. The individual test specimens, cut from six large panels, consist of 39 static specimens, 10 fracture mechanics specimens, and one each full size panel for compression stability and fracture mechanics testing. Tests are performed at temperatures of -54 C (-65 F), room temperature, and 260 C (500 F).

Time-Reversal Based Range Extension Technique for Ultra-Wideband (UWB) Sensors and Applications in Tactical Communications and Networking

DTIC Science & Technology

2009-07-16

Frequency (MHz) Figure 3.4: CABLE SMA/SMA 24" RG-316DS. CABLE SMA PLUG-PLUG HF -.086 8" 3.1. TRANSMITTER IMPLEMENTATION 13 Length: 8.0" (203.2mm) Color...Gray RG Type: Hand Formable .086 Connector: Type SMA Male to SMA Male Features: Shielded "• JI Figure 3.5: CABLE SMA PLUG-PLUG HF -.086 8...34 . • CABLE SMA PLUG-PLUG HF -.141 8" Length: 8.0" (203.2mm) Color: Gray RG Type: Hand Formable .141 14 CHAPTER 3. 2 BY I MISO SYSTEM DEVELOPMENT

Review of European Powder Metallurgy of Superalloys.

DTIC Science & Technology

1979-12-01

after suitable slag skiimming, atomization occurs through a ceramic nozzle. Powder falls through the atomizing tower and is collected in a water...shaped container for HIP. Superplastic bag forming is also being investigated( 2 7 ) , but few details are available. Glass cans have also been used for

Continuous Severe Plastic Deformation Processing of Aluminum Alloys

DOE Office of Scientific and Technical Information (OSTI.GOV)

Raghavan Srinivasan; Prabir K. Chaudhury; Balakrishna Cherukuri

2006-06-30

Metals with grain sizes smaller than 1-micrometer have received much attention in the past decade. These materials have been classified as ultra fine grain (UFG) materials (grain sizes in the range of 100 to 1000-nm) and nano-materials (grain size <100-nm) depending on the grain size. This report addresses the production of bulk UFG metals through the use of severe plastic deformation processing, and their subsequent use as stock material for further thermomechanical processing, such as forging. A number of severe plastic deformation (SPD) methods for producing bulk UFG metals have been developed since the early 1990s. The most promising ofmore » these processes for producing large size stock that is suitable for forging is the equal channel angular extrusion or pressing (ECAE/P) process. This process involves introducing large shear strain in the work-piece by pushing it through a die that consists of two channels with the same cross-sectional shape that meet at an angle to each other. Since the cross-sections of the two channels are the same, the extruded product can be re-inserted into the entrance channel and pushed again through the die. Repeated extrusion through the ECAE/P die accumulates sufficient strain to breakdown the microstructure and produce ultra fine grain size. It is well known that metals with very fine grain sizes (< 10-micrometer) have higher strain rate sensitivity and greater elongation to failure at elevated temperature, exhibiting superplastic behavior. However, this superplastic behavior is usually manifest at high temperature (> half the melting temperature on the absolute scale) and very low strain rates (< 0.0001/s). UFG metals have been shown to exhibit superplastic characteristics at lower temperature and higher strain rates, making this phenomenon more practical for manufacturing. This enables part unitization and forging more complex and net shape parts. Laboratory studies have shown that this is particularly true for UFG metals produced by SPD techniques. This combination of properties makes UFG metals produced by SPD very attractive as machining, forging or extrusion stock, both from the point of view of formability as well as energy and cost saving. However, prior to this work there had been no attempt to transfer these potential benefits observed in the laboratory scale to industrial shop floor. The primary reason for this was that the laboratory scale studies had been conducted to develop a scientific understanding of the processes that result in grain refinement during SPD. Samples that had been prepared in the laboratory scale were typically only about 10-mm diameter and 50-mm long (about 0.5-inch diameter and 2-inches long). The thrust of this project was three-fold: (i) to show that the ECAE/P process can be scaled up to produce long samples, i.e., a continuous severe plastic deformation (CSPD) process, (ii) show the process can be scaled up to produce large cross section samples that could be used as forging stock, and (iii) use the large cross-section samples to produce industrial size forgings and demonstrate the potential energy and cost savings that can be realized if SPD processed stock is adopted by the forging industry. Aluminum alloy AA-6061 was chosen to demonstrate the feasibility of the approach used. The CSPD process developed using the principles of chamber-less extrusion and drawing, and was demonstrated using rolling and wire drawing equipment that was available at Oak Ridge National Laboratory. In a parallel effort, ECAE/P dies were developed for producing 100-mm square cross section SPD billets for subsequent forging. This work was carried out at Intercontinental Manufacturing Co. (IMCO), Garland TX. Forging studies conducted with the ECAE/P billets showed that many of the potential benefits of using UFG material can be realized. In particular, the material yield can be increased, and the amount of material that is lost as scrap can be reduced by as much as 50%. Forging temperatures can also be reduced by over 150ºC, resulting in energy savings in the operation of billet heating furnaces. Looking at only the energy required to make forgings from stock materials, estimated energy savings associated with reduced scrap and lower furnace operating temperatures were greater than 40% if ECAE/P stock material was used instead of conventionally extruded stock. Subsequent heat treatment of the forged materials to the T6 condition showed that the mechanical properties of parts made from the ECAE/P stock material were the same as of those made from conventional extruded stock material. Therefore, the energy and cost savings benefits can be realized by the use SPD processed material as forging stock without sacrificing properties in the final part.« less

SPF/DB titanium concepts for structural efficiency foi HC

NASA Technical Reports Server (NTRS)

Wilson, V. E.

1982-01-01

Illustrations for a presentation on superplastic forming/diffusion bonding titanium design concepts are presented. Sandwich skin panels with hat section, semicircular corrugation, sine wave, and truss cores are shown. The fabrication of wing panels is illustrated, and applications to the design of advanced variable sweep bombers summarized.

Highly conductive thermoplastic composites for rapid production of fuel cell bipolar plates

DOEpatents

Huang, Jianhua [Blacksburg, VA; Baird, Donald G [Blacksburg, VA; McGrath, James E [Blacksburg, VA

2008-04-29

A low cost method of fabricating bipolar plates for use in fuel cells utilizes a wet lay process for combining graphite particles, thermoplastic fibers, and reinforcing fibers to produce a plurality of formable sheets. The formable sheets are then molded into a bipolar plates with features impressed therein via the molding process. The bipolar plates formed by the process have conductivity in excess of 150 S/cm and have sufficient mechanical strength to be used in fuel cells. The bipolar plates can be formed as a skin/core laminate where a second polymer material is used on the skin surface which provides for enhanced conductivity, chemical resistance, and resistance to gas permeation.

Improving hydro-formability of stainless steel tubes by tube channel pressing

NASA Astrophysics Data System (ADS)

Kitano, Y.; Yuasa, M.; Miyamoto, H.; Farshidi, M. H.; Bagherpour, E.

2017-05-01

Tube channel pressing (TCP), which is one of the severe plastic deformation (SPD) technologies to refine grain size into submicron size for tubular materials, have been applied to ferritic stainless steel tubes for one pass, in order to alleviate ridging and enhance the hydro-formability. It was found that grain-scale shear bands were introduced by one-pass TCP, and texture and microstructure was successfully modified by promoting recrystallization of deformation microstructure, which is otherwise hard-to-recrystallize, in the post-TCP annealing. Elongation to failure, strain-hardening exponent (n-value) and Lankford values of both longitudinal and circumferential directions increased in comparison to with the tube fabricated by conventional process.

Novel High Temperature and Radiation Resistant Infrared Glasses and Optical Fibers for Sensing in Advanced Small Modular Reactors

DOE Office of Scientific and Technical Information (OSTI.GOV)

Ballato, John

One binary and three series of ternary non-oxide pure sulfide glasses compositions were investigated with the goal of synthesizing new glasses that exhibit high glass transition (Tg) and crystallization (Tc) temperatures, infrared transparency, and reliable glass formability. The binary glass series consisted of Ges 2 and La 2S 3 and the three glass series in the x(nBaS + mLa2S3) + (1-2x)GeS2 ternary system have BaS:La2S3 modifier ratios of 1:1, 1:2, and 2:1 with . With these glasses, new insights were realized as to how ionic glasses form and how glass modifiers affect both structure and glass formability. All synthesized compositionsmore » were characterized by Infrared (IR) and Raman spectroscopies and differential thermal analysis (DTA) to better understand the fundamental structure, optical, and thermal characteristics of the glasses. After a range of these glasses were synthesized, optimal compositions were formed into glass disks and subjected to gamma irradiation. Glass disks were characterized both before and after irradiation by microscope imaging, measuring the refractive index, density, and UV-VIS-IR transmission spectra. The final total dose the samples were subjected to was ~2.5 MGy. Ternary samples showed a less than 0.4% change in density and refractive index and minimal change in transmission window. The glasses also resisted cracking as seen in microscope images. Overall, many glass compositions were developed that possess operating temperatures above 500 °C, where conventional chalcogenide glasses such as As2S3 and have T gs from ~200-300 °C, and these glasses have a greater than Tc – Tg values larger than 100 °C and this shows that these glasses have good thermal stability of Tg such that they can be fabricated into optical fibers and as such can be considered candidates for high temperature infrared fiber optics. Initial fiber fabrication efforts showed that selected glasses could be drawn but larger samples would be needed for further development and optimization« less

Investigation into the Fiber Orientation Effect on the Formability of GLARE Materials in the Stamp Forming Process

NASA Astrophysics Data System (ADS)

Liu, Shichen; Lang, Lihui; Sherkatghanad, Ehsan; Wang, Yao; Xu, Wencai

2018-04-01

Glass-reinforced aluminum laminate (GLARE) is a new class of fiber metal laminates (FMLs) which has the advantages such as high tensile strength, outstanding fatigue, impact resistance, and excellent corrosion properties. GLARE has been extensively applied in advanced aerospace and automobile industries. However, the deformation behavior of the glass fiber during forming must be studied to the benefits of the good-quality part we form. In this research, we focus on the effect of fiber layer orientation on the GLARE laminate formability in stamp forming process. Experimental and numerical analysis of stamping a hemisphere part in different fiber orientation is investigated. The results indicate that unidirectional and multi-directional fiber in the middle layer make a significant effect on the thinning and also surface forming quality of the three layer sheet. Furthermore, the stress-strain distribution of the aluminum alloy and the unique anisotropic property of the fiber layer exhibit that fiber layer orientation can also affect the forming depths as well as the fracture modes of the laminate. According to the obtained results, it is revealed that multi-directional fiber layers are a good alternative compared to the unidirectional fibers especially when a better formability is the purpose.

Formability and mechanical properties of porous titanium produced by a moldless process.

PubMed

Naito, Yoshihito; Bae, Jiyoung; Tomotake, Yoritoki; Hamada, Kenichi; Asaoka, Kenzo; Ichikawa, Tetsuo

2013-08-01

Tailor-made porous titanium implants show great promise in both orthopedic and dental applications. However, traditional powder metallurgical processes require a high-cost mold, making them economically unviable for producing unique devices. In this study, a mixture of titanium powder and an inlay wax binder was developed for moldless forming and sintering. The formability of the mixture, the dimensional changes after sintering, and the physical and mechanical properties of the sintered porous titanium were evaluated. A 90:10 wt % mixture of Ti powder and wax binder was created manually at 70°C. After debindering, the specimen was sintered in Ar at 1100°C without any mold for 1, 5, and 10 h. The shrinkage, porosity, absorption ratio, bending and compressive strength, and elastic modulus were measured. The bending strength (135-356 MPa), compression strength (178-1226 MPa), and elastic modulus (24-54 GPa) increased with sintering time; the shrinkage also increased, whereas the porosity (from 37.1 to 29.7%) and absorption ratio decreased. The high formability of the binder/metal powder mixture presents a clear advantage for fabricating tailor-made bone and hard tissue substitution units. Moreover, the sintered compacts showed high strength and an elastic modulus comparable to that of cortical bone. Copyright © 2013 Wiley Periodicals, Inc.

Radiographic evaluation of acute distal radius fracture stability: A comparative cadaveric study between a thermo-formable bracing system and traditional fiberglass casting.

PubMed

Santoni, Brandon G; Aira, Jazmine R; Diaz, Miguel A; Kyle Stoops, T; Simon, Peter

2017-08-01

Distal radius fractures are common musculoskeletal injuries and many can be treated non-operatively with cast immobilization. A thermo-formable brace has been developed for management of such fractures, but no data exist regarding its comparative stabilizing efficacy to fiberglass casting. A worst-case distal radius fracture was created in 6 cadaveric forearms. A radiolucent loading fixture was created to apply cantilever bending/compression loads ranging from 4.5N to 66.7N across the simulated fracture in the: (1) non-stabilized, (2) braced; and (3) casted forearms, each forearm serving as its own control. Fracture fragment translations and rotations were measured radiographically using orthogonal radiographs and a 2D-3D, CT-based transformation methodology. Under 4.5N of load in the non-stabilized condition, average sagittal plane rotation and 3D center of mass translation of the fracture fragment were 12.3° and 5.3mm, respectively. At the 4.5N load step, fragment rotation with the brace (avg. 0.0°) and cast (0.1°) reduced sagittal plane rotation compared to the non-stabilized forearm (P<0.001). There were no significant differences in measured sagittal plane fracture fragment rotations or 3D fragment translations between the brace or cast at any of the four load steps (4.5N, 22.2N, 44.5N, and 66.7N, P≥0.138). In this in vitro radiographic study utilizing 6 cadaveric forearms with simulated severe-case, unstable and comminuted distal radius fractures, the thermo-formable brace stabilized the fracture in a manner that was not radiographically or biomechanically different from traditional fiberglass casting. Study results support the use of the thermo-formable brace clinically. Copyright © 2017 Elsevier Ltd. All rights reserved.

Characterization of the austenitic stability of metastable austenitic stainless steel with regard to its formability

NASA Astrophysics Data System (ADS)

Schneider, Matthias; Liewald, Mathias

2018-05-01

During the last decade, the stainless steel market showed a growing volume of 3-5% p.a.. The austenitic grades are losing market shares to ferritic or 200-series grades due to the high nickel price, but still playing the most important role within the stainless steel market. Austenitic stainless steel is characterized by the strain-induced martensite formation, causing the TRIP-effect (Transformation Induced Plasticity) which is responsible for good formability and high strength. The TRIP-effect itself is highly dependent on the forming temperature, the strain as well as the chemical composition which has a direct influence on the stability of the austenite. Today the austenitic stability is usually characterized by the so called Md30-temperature, which was introduced by Angel and enhanced by several researches, particularly Nohara. It is an empirical formula based on the chemical composition and the grain size of a given material, calculating the temperature which is necessary to gain a 50 % martensite formation after 30 % of elongation in a tensile test. A higher Md30-temperature indicates a lower stability and therefore a higher tendency towards martensite formation. The main disadvantage of Md30 -temperature is the fact that it is not based on forming parameters and only describes a single point instead of the whole forming process. In this paper, an experimental set up for measuring martensite and temperature evolution in a non-isothermal tensile test is presented, which is based on works of Hänsel and Schmid. With this set up, the martensite formation rate for different steels of the steel grade EN 1.4301 and EN 1.4310 is measured. Based on these results a new austenitic stability criterion is defined. This criterion and the determined Md30-temperatures are related to the stretch formability of the materials. The results show that the new IFU criterion is with regard to the formability a much more useful characteristic number for metastable austenitic steels than the Md30-temperature.

Power metallurgy approaches to high temperature components for gas turbine engines

NASA Technical Reports Server (NTRS)

Probst, H. B.

1974-01-01

Work conducted by NASA and NASA contractors on prealloyed superalloy powders and materials strengthened by oxide dispersion is reviewed. Fabrication, tensile strength, superplasticity, grain growth control, stress rupture life, and grain-size and dispersion-level effects are covered. Distinct strength advantages of powder metallurgy superalloys over conventional wrought alloys are noted.

Superplasticity in Fine-Grained Ceramics

DTIC Science & Technology

1994-01-31

Stabilized, Tetragonal Zirconia," Acta Metall. Mater., 39(12), (1991), pp. 3227-3236. 10. B. Kellett, P. Carry, and A. Mocellin , "Extrusion of Tet-ZrO2...F. Wakai, S. Sakaguchi, and H. Kato, J. Ceram. Soc. Jap., 94, 72 (1986). 8. B. Kellett, P. Carry, and A. Mocellin , J. Amer. Ceram. Soc., 74, 1922

Connections: Superplasticity, Damascus Steels, Laminated Steels, and Carbon Dating

NASA Astrophysics Data System (ADS)

Wadsworth, Jeffrey

2016-12-01

In this paper, a description is given of the connections that evolved from the initial development of a family of superplastic plain carbon steels that came to be known as Ultra-High Carbon Steels (UHCS). It was observed that their very high carbon contents were similar, if not identical, to those of Damascus steels. There followed a series of attempts to rediscover how the famous patterns found on Damascus steels blades were formed. At the same time, in order to improve the toughness at room temperature of the newly-developed UHCS, laminated composites were made of alternating layers of UHCS and mild steel (and subsequently other steels and other metals). This led to a study of ancient laminated composites, the motives for their manufacture, and the plausibility of some of the claims relating to the number of layers in the final blades. One apparently ancient laminated composite, recovered in 1837 from the great pyramid of Giza which was constructed in about 2750 B.C., stimulated a carbon dating study of ancient steels. The modern interest in "Bladesmithing" has connections back to many of these ancient weapons.

Simulation for analysis and control of superplastic forming. Final report

DOE Office of Scientific and Technical Information (OSTI.GOV)

Zacharia, T.; Aramayo, G.A.; Simunovic, S.

1996-08-01

A joint study was conducted by Oak Ridge National Laboratory (ORNL) and the Pacific Northwest Laboratory (PNL) for the U.S. Department of Energy-Lightweight Materials (DOE-LWM) Program. the purpose of the study was to assess and benchmark the current modeling capabilities with respect to accuracy of predictions and simulation time. Two modeling capabilities with respect to accuracy of predictions and simulation time. Two simulation platforms were considered in this study, which included the LS-DYNA3D code installed on ORNL`s high- performance computers and the finite element code MARC used at PNL. both ORNL and PNL performed superplastic forming (SPF) analysis on amore » standard butter-tray geometry, which was defined by PNL, to better understand the capabilities of the respective models. The specific geometry was selected and formed at PNL, and the experimental results, such as forming time and thickness at specific locations, were provided for comparisons with numerical predictions. Furthermore, comparisons between the ORNL simulation results, using elasto-plastic analysis, and PNL`s results, using rigid-plastic flow analysis, were performed.« less

Superplastic Forming/Diffusion Bonding Without Interlayer of 5A90 Al-Li Alloy Hollow Double-Layer Structure

NASA Astrophysics Data System (ADS)

Jiang, Shaosong; Jia, Yong; Lu, Zhen; Shi, Chengcheng; Zhang, Kaifeng

2017-09-01

The hollow double-layer structure of 5A90 Al-Li alloy was fabricated by SPF/DB process in this study. The characteristics and mechanism of 5A90 Al-Li alloy with respect to superplasticity and diffusion bonding were investigated. Tensile tests showed that the optimal elongation of tensile specimens was 243.97% at the temperature of 400 °C and the strain rate of 0.001 s-1. Effect of the surface roughness, bonding temperature and bonding time to determine the microstructure and mechanical properties of diffusion bonding joints was investigated, and the optimum bonding parameters were 540 °C/2.5 h/Ra18. Through the finite element simulation, it could be found that the SPF/DB process of hollow double-layer structure was feasible. The hollow double-layer structure of 5A90 Al-Li alloy was manufactured, showing that the thickness distribution of the bonding area was uniform and the thinnest part was the round corner. The SEM images of diffusion bonding joints showed that sound bonding interfaces were obtained in which no discontinuity existed.

The relationships between residual stress relaxation and texture development in AZ31 Mg alloys via the vibratory stress relief technique

DOE Office of Scientific and Technical Information (OSTI.GOV)

Wang, Jia-Siang, E-mail: andy304312003@yahoo.com.tw; Hsieh, Chih-Chun, E-mail: jeromehsieh@gmail.com; Lai, Hsuan-Han, E-mail: g099066020@mail.nchu.edu.tw

2015-01-15

A systematic study of residual stress relaxation and the texture evolution of cold-rolled AZ31 Mg alloys using the vibratory stress relief technique with a simple cantilever beam vibration system was performed using a high-resolution X-ray diffractometer and a portable X-ray residual stress analyzer. The effects of vibrational stress excitation on the surface residual stress distribution and on the texture of pole figures (0002) occurring during the vibratory stress relief were examined. Compared with the effects corresponding to the same alloy under non-vibration condition, it can be observed that the uniform surface residual stress distribution and relaxation of the compressive residualmore » stress in the stress concentration zone were observed rather than all of the residual stresses being eliminated. Furthermore, with an increase in the vibrational aging time, the compressive residual stress, texture density, and (0002) preferred orientation increased first and then decreased. It should be underlined that the vibratory stress relief process for the vibrational aging time of more than 10 min is able to weaken the strong basal textures of AZ31 Mg alloys, which is valuable for enhancement of their formability and is responsible for an almost perfect 3D-Debye–Scherrer ring. - Highlights: • 3D-Debye ring about VSR technique is not discussed in the existing literature. • A newly developed VSR method is suitable for small or thin workpieces. • The cosα method accurately and effectively determines the residual stresses. • The VSR technique is valuable for enhancement of their formability. • The texture and preferred orientation change with the vibrational aging time.« less

Application of sintered titanium alloys to metal denture bases: a study of titanium powder sheets for complete denture base.

PubMed

Doi, H; Harrori, M; Hasegawa, K; Yoshinari, M; Kawada, E; Oda, Y

2001-02-01

The purpose of this study was the fabrication of titanium powder sheets to enable the application of sintered titanium alloys as metal denture bases. The effects of titanium particle shape and size, binder content, and plasticizer content on the surface smoothness, tensile strength and elongation of titanium powder sheets was investigated. To select a suitable ratio of powdered metal contents for application as a metal denture base, the effects of aluminum content in Ti sheets and various other powder metal contents in Ti-Al sheets on the density, sintering shrinkage, and bending strength were evaluated. Based on the results of the above experiments, we developed a mixed powder sheet composed of 83Ti-7Al-10Cr with TA45 titanium powder (atomized, -45 microm), and 8 mass% binder content. This titanium alloy sheet had good formability and ductility. Its sintered titanium alloy had a density of 3.2 g/cm3, sintering shrinkage of 3.8%, and bending strength of 403 MPa. The titanium alloy sheet is clinically acceptable for fabricating denture bases.

Deep focus earthquakes in the laboratory

NASA Astrophysics Data System (ADS)

Schubnel, Alexandre; Brunet, Fabrice; Hilairet, Nadège; Gasc, Julien; Wang, Yanbin; Green, Harry W., II

2014-05-01

While the existence of deep earthquakes have been known since the 1920's, the essential mechanical process responsible for them is still poorly understood and remained one of the outstanding unsolved problems of geophysics and rock mechanics. Indeed, deep focus earthquake occur in an environment fundamentally different from that of shallow (<100 km) earthquakes. As pressure and temperature increase with depth however, intra-crystalline plasticity starts to dominate the deformation regime so that rocks yield by plastic flow rather than by brittle fracturing. Olivine phase transitions have provided an attractive alternative mechanism for deep focus earthquakes. Indeed, the Earth mantle transition zone (410-700km) is the locus of the two successive polymorphic transitions of olivine. Such scenario, however, runs into the conceptual barrier of initiating failure in a pressure (P) and temperature (T) regime where deviatoric stress relaxation is expected to be achieved through plastic flow. Here, we performed laboratory deformation experiments on Germanium olivine (Mg2GeO4) under differential stress at high pressure (P=2-5GPa) and within a narrow temperature range (T=1000-1250K). We find that fractures nucleate at the onset of the olivine to spinel transition. These fractures propagate dynamically (i.e. at a non-negligible fraction of the shear wave velocity) so that intense acoustic emissions are generated. Similar to deep-focus earthquakes, these acoustic emissions arise from pure shear sources, and obey the Gutenberg-Richter law without following Omori's law. Microstructural observations prove that dynamic weakening likely involves superplasticity of the nanocrystalline spinel reaction product at seismic strain rates. Although in our experiments the absolute stress value remains high compared to stresses expected within the cold core of subducted slabs, the observed stress drops are broadly consistent with those calculated for deep earthquakes. Constant differential stress conditions at failure over a wide range of confinement (2-5GPa) strongly suggest that transformational faulting is largely independent of normal stress and thus involves non-frictional processes. We suggest that rupture nucleation is controlled by dislocation density and spinel nucleation kinetics, while propagation is controlled by superplastic flow. High stress and high dislocation density conditions can be met in a cold subducting slab full of metastable olivine, due to stress concentrations at the micro and mesoscopic scales because of buckling, folding, and/or inherited fractures. This is particularly true in the Tonga-Kermadec region for instance, for which the largest catalog of deep focus earthquake is available.

The Bendability of Ultra High strength Steels

NASA Astrophysics Data System (ADS)

Hazra, S. K.; Efthymiadis, P.; Alamoudi, A.; Kumar, R. L. V.; Shollock, B.; Dashwood, R.

2016-08-01

Automotive manufacturers have been reducing the weight of their vehicles to meet increasingly stringent environmental legislation that reflects public demand. A strategy is to use higher strength materials for parts with reduced cross-sections. However, such materials are less formable than traditional grades. The frequent result is increased processing and piece costs. 3D roll forming is a novel and flexible process: it is estimated that a quarter of the structure of a vehicle can be made with a single set of tooling. Unlike stamping, this process requires material with low work hardening rates. In this paper, we present results of ultra high strength steels that have low elongation in a tension but display high formability in bending through the suppression of the necking response.

Nanostructural hierarchy increases the strength of aluminium alloys.

PubMed

Liddicoat, Peter V; Liao, Xiao-Zhou; Zhao, Yonghao; Zhu, Yuntian; Murashkin, Maxim Y; Lavernia, Enrique J; Valiev, Ruslan Z; Ringer, Simon P

2010-09-07

Increasing the strength of metallic alloys while maintaining formability is an interesting challenge for enabling new generations of lightweight structures and technologies. In this paper, we engineer aluminium alloys to contain a hierarchy of nanostructures and possess mechanical properties that expand known performance boundaries-an aerospace-grade 7075 alloy exhibits a yield strength and uniform elongation approaching 1 GPa and 5%, respectively. The nanostructural architecture was observed using novel high-resolution microscopy techniques and comprises a solid solution, free of precipitation, featuring (i) a high density of dislocations, (ii) subnanometre intragranular solute clusters, (iii) two geometries of nanometre-scale intergranular solute structures and (iv) grain sizes tens of nanometres in diameter. Our results demonstrate that this novel architecture offers a design pathway towards a new generation of super-strong materials with new regimes of property-performance space.

Comparative Study of Several Energy Dissipating Devices

NASA Astrophysics Data System (ADS)

Abdul-Latif, A.

2011-11-01

Large plastic lateral collapse problem of two geometrically identical hollow cylinders under compressive load is of particular interest in this work, since, the energy absorbed can be characterized by a smooth loaded deflection relation, and these tubes are also easier to build than most other devices. Cylinders of various geometrical parameters (i.e., inside/outside diameter ratios: R = di/do ranging from 0 to 0.473) are used having the same cross-sectional area and length. Superplastic material used in this study has a considerably sensitivity to the quasi-static strain rate in the range of (10-5 to 10-3/s). Hence, this material could be employed as a representative material to simulate the classical engineering material behavior under high strain rate. Comparative study of different structural situations is conducted using four energy dissipating devices designed and investigated by the author in previous works. They are: (1) two geometrically identical cylinders made of superplastic tin-lead alloy can freely expand along their sides and lengths; (2) two cylinders are the same as in (1) but not allowed to expand along their sides and lengths; (3) one cylinder is made from superplastic and the other made from steel and free to deform along its sides and length; (4) the same as in (3) but the cylinder is not allowed to expand along its sides and length. Based on the obtained experimental results, the features of each device in dissipating the energy during the large plastic collapse are investigated. It is concluded that the energy absorbed for a given system decreases with the increase of the R ratio. It is recognized that the highest absorbed energy is obtained in the constrained situation with deformable non-deformable compared to the other situations. Moreover, through the finite element simulations, the flow mechanism in each device is studied and compared to the experimental results.

Nanoscale alloys and core-shell materials: Model predictions of the nanostructure and mechanical properties

NASA Astrophysics Data System (ADS)

Zhurkin, E. E.; van Hoof, T.; Hou, M.

2007-06-01

Atomic scale modeling methods are used to investigate the relationship between the properties of clusters of nanometer size and the materials that can be synthesized by assembling them. The examples of very different bimetallic systems are used. The first one is the Ni3Al ordered alloy and the second is the AgCo core-shell system. While the Ni3Al cluster assembled materials modeling is already reported in our previous work, here we focus on the prediction of new materials synthesized by low energy deposition and accumulation of AgCo clusters. It is found that the core-shell structure is preserved by deposition with energies typical of low energy cluster beam deposition, although deposition may induce substantial cluster deformation. In contrast with Ni3Al deposited cluster assemblies, no grain boundary between clusters survives deposition and the silver shells merge into a noncrystalline system with a layered structure, in which the fcc Co grains are embedded. To our knowledge, such a material has not yet been synthesized experimentally. Mechanical properties are discussed by confronting the behaviors of Ni3Al and AgCo under the effect of a uniaxial load. To this end, a molecular dynamics scheme is established in view of circumventing rate effects inherent to short term modeling and thereby allowing to examine large plastic deformation mechanisms. Although the mechanisms are different, large plastic deformations are found to improve the elastic properties of both the Ni3Al and AgCo systems by stabilizing their nanostructure. Beyond this improvement, when the load is further increased, the Ni3Al system displays reduced ductility while the AgCo system is superplastic. The superplasticity is explained by the fact that the layered structure of the Ag system is not modified by the deformation. Some coalescence of the Co grains is identified as a geometrical effect and is suggested to be a limiting factor to superplasticity.

Manifold free multiple sheet superplastic forming

DOEpatents

Elmer, John W.; Bridges, Robert L.

2001-01-01

Fluid-forming compositions in a container attached to enclosed adjacent sheets are heated to relatively high temperatures to generate fluids (gases) that effect inflation of the sheets. Fluid rates to the enclosed space between the sheets can be regulated by the canal from the container. Inflated articles can be produced by a continuous, rather than batch-type, process.

New trends in metal forming in the USA

NASA Astrophysics Data System (ADS)

1982-05-01

The use of lasers in sheet metal stamping, hydraulic presses, cold pressing, and deformation of titanium alloy to produce components which do not require subsequent machining are discussed. Superplastic deformation techniques could lead to cost savings of 90% in the aerospace industry. Precision forging and welding technologies can considerably reduce raw material costs, but investment costs are high.

Manifold free multiple sheet superplastic forming

DOEpatents

Elmer, John W.; Bridges, Robert L.

2004-01-13

Fluid-forming compositions in a container attached to enclosed adjacent sheets are heated to relatively high temperatures to generate fluids (gases) that effect inflation of the sheets. Fluid rates to the enclosed space between the sheets can be regulated by the canal from the container. Inflated articles can be produced by a continuous, rather than batch-type, process.

Formability prediction for AHSS materials using damage models

NASA Astrophysics Data System (ADS)

Amaral, R.; Santos, Abel D.; José, César de Sá; Miranda, Sara

2017-05-01

Advanced high strength steels (AHSS) are seeing an increased use, mostly due to lightweight design in automobile industry and strict regulations on safety and greenhouse gases emissions. However, the use of these materials, characterized by a high strength to weight ratio, stiffness and high work hardening at early stages of plastic deformation, have imposed many challenges in sheet metal industry, mainly their low formability and different behaviour, when compared to traditional steels, which may represent a defying task, both to obtain a successful component and also when using numerical simulation to predict material behaviour and its fracture limits. Although numerical prediction of critical strains in sheet metal forming processes is still very often based on the classic forming limit diagrams, alternative approaches can use damage models, which are based on stress states to predict failure during the forming process and they can be classified as empirical, physics based and phenomenological models. In the present paper a comparative analysis of different ductile damage models is carried out, in order numerically evaluate two isotropic coupled damage models proposed by Johnson-Cook and Gurson-Tvergaard-Needleman (GTN), each of them corresponding to the first two previous group classification. Finite element analysis is used considering these damage mechanics approaches and the obtained results are compared with experimental Nakajima tests, thus being possible to evaluate and validate the ability to predict damage and formability limits for previous defined approaches.

Inverse Analysis to Formability Design in a Deep Drawing Process

NASA Astrophysics Data System (ADS)

Buranathiti, Thaweepat; Cao, Jian

Deep drawing process is an important process adding values to flat sheet metals in many industries. An important concern in the design of a deep drawing process generally is formability. This paper aims to present the connection between formability and inverse analysis (IA), which is a systematical means for determining an optimal blank configuration for a deep drawing process. In this paper, IA is presented and explored by using a commercial finite element software package. A number of numerical studies on the effect of blank configurations to the quality of a part produced by a deep drawing process were conducted and analyzed. The quality of the drawing processes is numerically analyzed by using an explicit incremental nonlinear finite element code. The minimum distance between elemental principal strains and the strain-based forming limit curve (FLC) is defined as tearing margin to be the key performance index (KPI) implying the quality of the part. The initial blank configuration has shown that it plays a highly important role in the quality of the product via the deep drawing process. In addition, it is observed that if a blank configuration is not greatly deviated from the one obtained from IA, the blank can still result a good product. The strain history around the bottom fillet of the part is also observed. The paper concludes that IA is an important part of the design methodology for deep drawing processes.

Parameter Calibration of GTN Damage Model and Formability Analysis of 22MnB5 in Hot Forming Process

NASA Astrophysics Data System (ADS)

Ying, Liang; Liu, Wenquan; Wang, Dantong; Hu, Ping

2017-11-01

Hot forming of high strength steel at elevated temperatures is an attractive technology to achieve the lightweight of vehicle body. The mechanical behavior of boron steel 22MnB5 strongly depends on the variation of temperature which makes the process design more difficult. In this paper, the Gurson-Tvergaard-Needleman (GTN) model is used to study the formability of 22MnB5 sheet at different temperatures. Firstly, the rheological behavior of 22MnB5 is analyzed through a series of hot tensile tests at a temperature range of 600-800 °C. Then, a detailed process to calibrate the damage parameters is given based on the response surface methodology and genetic algorithm method. The GTN model together with the damage parameters calibrated is then implemented to simulate the deformation and damage evolution of 22MnB5 in the process of high-temperature Nakazima test. The capability of the GTN model as a suitable tool to evaluate the sheet formability is confirmed by comparing experimental and calculated results. Finally, as a practical application, the forming limit diagram of 22MnB5 at 700 °C is constructed using the Nakazima simulation and Marciniak-Kuczynski (M-K) model, respectively. And the simulation integrated GTN model shows a higher reliability by comparing the predicted results of these two approaches with the experimental ones.

Characteristics of the aluminum alloy sheets for forming and application examples

NASA Astrophysics Data System (ADS)

Uema, Naoyuki; Asano, Mineo

2013-12-01

In this paper, the characteristics and application examples of aluminum alloy sheets developed for automotive parts by Sumitomo Light Metal are described. For the automotive closure panels (ex., hood, back-door), an Al-Mg-Si alloy sheet having an excellent hemming performance was developed. The cause of the occurrence and the propagation of cracks by bending were considered to be the combined effect of the shear bands formed across several crystal grains and the micro-voids formed around the second phase particles. By reducing the shear band formation during bending by controlling the crystallographic texture, the Al-Mg-Si alloy sheets showed an excellent hemming performance. For the automotive outer panels (ex., roof, fender, trunk-lid), an Al-Mg alloy sheet, which has both a good hot blow formability and excellent surface appearance after hot blow forming was developed, and hot blow forming technology was put to practical use using this developed Al-Mg alloy sheet. For automotive heat insulators, a high ductile Al-Fe alloy sheet was developed. The heat insulator, which integrated several panels, was put into practical use using this developed Al-Fe alloy sheet. The textured sheet was often used as a heat insulator in order to reduce the thickness of the aluminum alloy sheet and obtain good press formability. The new textured sheet, which has both high rigidity and good press formability for heat insulators, was developed by FE analysis.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Arul Kumar, Mariyappan; Beyerlein, Irene Jane; McCabe, Rodney James

Materials with a hexagonal close-packed (hcp) crystal structure such as Mg, Ti and Zr are being used in the transportation, aerospace and nuclear industry, respectively. Material strength and formability are critical qualities for shaping these materials into parts and a pervasive deformation mechanism that significantly affects their formability is deformation twinning. The interaction between grain boundaries and twins has an important influence on the deformation behaviour and fracture of hcp metals. Here, statistical analysis of large data sets reveals that whether twins transmit across grain boundaries depends not only on crystallography but also strongly on the anisotropy in crystallographic slip.more » As a result, we show that increases in crystal plastic anisotropy enhance the probability of twin transmission by comparing the relative ease of twin transmission in hcp materials such as Mg, Zr and Ti.« less

Grain neighbour effects on twin transmission in hexagonal close-packed materials

NASA Astrophysics Data System (ADS)

Arul Kumar, M.; Beyerlein, I. J.; McCabe, R. J.; Tomé, C. N.

2016-12-01

Materials with a hexagonal close-packed (hcp) crystal structure such as Mg, Ti and Zr are being used in the transportation, aerospace and nuclear industry, respectively. Material strength and formability are critical qualities for shaping these materials into parts and a pervasive deformation mechanism that significantly affects their formability is deformation twinning. The interaction between grain boundaries and twins has an important influence on the deformation behaviour and fracture of hcp metals. Here, statistical analysis of large data sets reveals that whether twins transmit across grain boundaries depends not only on crystallography but also strongly on the anisotropy in crystallographic slip. We show that increases in crystal plastic anisotropy enhance the probability of twin transmission by comparing the relative ease of twin transmission in hcp materials such as Mg, Zr and Ti.

Grain neighbour effects on twin transmission in hexagonal close-packed materials.

PubMed

Arul Kumar, M; Beyerlein, I J; McCabe, R J; Tomé, C N

2016-12-19

Materials with a hexagonal close-packed (hcp) crystal structure such as Mg, Ti and Zr are being used in the transportation, aerospace and nuclear industry, respectively. Material strength and formability are critical qualities for shaping these materials into parts and a pervasive deformation mechanism that significantly affects their formability is deformation twinning. The interaction between grain boundaries and twins has an important influence on the deformation behaviour and fracture of hcp metals. Here, statistical analysis of large data sets reveals that whether twins transmit across grain boundaries depends not only on crystallography but also strongly on the anisotropy in crystallographic slip. We show that increases in crystal plastic anisotropy enhance the probability of twin transmission by comparing the relative ease of twin transmission in hcp materials such as Mg, Zr and Ti.

Solute effect on basal and prismatic slip systems of Mg.

PubMed

Moitra, Amitava; Kim, Seong-Gon; Horstemeyer, M F

2014-11-05

In an effort to design novel magnesium (Mg) alloys with high ductility, we present a first principles data based on the Density Functional Theory (DFT). The DFT was employed to calculate the generalized stacking fault energy curves, which can be used in the generalized Peierls-Nabarro (PN) model to study the energetics of basal slip and prismatic slip in Mg with and without solutes to calculate continuum scale dislocation core widths, stacking fault widths and Peierls stresses. The generalized stacking fault energy curves for pure Mg agreed well with other DFT calculations. Solute effects on these curves were calculated for nine alloying elements, namely Al, Ca, Ce, Gd, Li, Si, Sn, Zn and Zr, which allowed the strength and ductility to be qualitatively estimated based on the basal dislocation properties. Based on our multiscale methodology, a suggestion has been made to improve Mg formability.

Tensile strength of ramie yarn (spinning by machine)/HDPE thermoplastic matrix composites

DOE Office of Scientific and Technical Information (OSTI.GOV)

Banowati, Lies, E-mail: liesbano@gmail.com; Hadi, Bambang K., E-mail: bkhadi@ae.itb.ac.id; Suratman, Rochim, E-mail: rochim@material.itb.ac.id

2016-03-29

Technological developments should be trooped to prevent a gap between technology and environmental sustainability, then it needs to be developed “Green technology”. In this research is making of green composites which use natural fiber ramie as reinforcement. Whereas the matrix used was HDPE (High Density Polyethylene) thermoplastic polymer which could be recycled and had a good formability and flexibility. The ramie yarns and fibers for unidirectional (0°) direction respectively were mixed with HDPE powder and processed using hot compression molding. The surface morphology was observed by SEM (Scanning Electrone Microscopy). Results showed that both tensile strength of the ramie fiber/HDPEmore » composites increased in comparison with the ramie yarn (spinning by machine)/HDPE composites. However, the ramie yarn (spinning by machine)/HDPE composites have a good producibility for wider application. Analysis of the test results using the Weibull distribution as approaches to modeling the reliability of the specimens.« less

CAE Based Die Face Engineering Development to Contribute to the Revitalization of the Tool & Die Industry

NASA Astrophysics Data System (ADS)

Tang, Arthur; Lee, Wing C.; St. Pierre, Shawn; He, Jeanne; Liu, Kesu; Chen, Chin C.

2005-08-01

Over the past two decades, the Computer Aided Engineering (CAE) tools have emerged as one of the most important engineering tools in various industries, due to its flexibility and accuracy in prediction. Nowadays, CAE tools are widely used in the sheet metal forming industry to predict the forming feasibility of a wide variety of complex components, ranging from aerospace and automotive components to household products. As the demand of CAE based formability accelerates, the need for a robust and streamlined die face engineering tool becomes more crucial, especially in the early stage when the tooling layout is not available, but a product design decision must be made. Ability to generate blank, binder and addendum surfaces with an appropriate layout of Drawbead, Punch Opening Line, Trim Line are the primary features and functions of a CAE based die face engineering tool. Once the die face layout is ready, a formability study should be followed to verify the die face layout is adequate to produce a formable part. If successful, the established die face surface should be exported back to the CAD/CAM environment to speed up the tooling and manufacturing design process with confidence that this particular part is formable with this given die face. With a CAE tool as described above, the tool & die industry will be greatly impacted as the processes will enable the bypass of hardware try-out and shorten the overall vehicle production timing. The trend has shown that OEMs and first tiers will source to low cost producers in the world which will have a negative impact to the traditional tool & die makers in the developed countries. CAE based tool as described should be adopted, along with many other solutions, in order to maintain efficiency of producing high quality product and meeting time-to-market requirements. This paper will describe how a CAE based die face engineering (DFE) tool could be further developed to enable the traditional tool & die makers to meet the challenge ahead.

The mechanical properties and microstructures of vanadium bearing high strength dual phase steels processed with continuous galvanizing line simulations

NASA Astrophysics Data System (ADS)

Gong, Yu

For galvanized or galvannealed steels to be commercially successful, they must exhibit several attributes: (i) easy and inexpensive processing in the hot mill, cold mill and on the coating line, (ii) high strength with good formability and spot weldability, and (iii) good corrosion resistance. At the beginning of this thesis, compositions with a common base but containing various additions of V or Nb with or without high N were designed and subjected to Gleeble simulations of different galvanizing(GI), galvannealing(GA) and supercooling processing. The results revealed the phase balance was strongly influenced by the different microalloying additions, while the strengths of each phase were somewhat less affected. Our research revealed that the amount of austenite formed during intercritical annealing can be strongly influenced by the annealing temperature and the pre-annealing conditions of the hot band (coiling temperature) and cold band (% cold reduction). In the late part of this thesis, the base composition was a low carbon steel which would exhibit good spot weldability. To this steel were added two levels of Cr and Mo for strengthening the ferrite and increasing the hardenability of intercritically formed austenite. Also, these steels were produced with and without the addition of vanadium in an effort to further increase the strength. Since earlier studies revealed a relationship between the nature of the starting cold rolled microstructure and the response to CGL processing, the variables of hot band coiling temperature and level of cold reduction prior to annealing were also studied. Finally, in an effort to increase strength and ductility of both the final sheet (general formability) and the sheared edges of cold punched holes (local formability), a new thermal path was developed that replaced the conventional GI ferrite-martensite microstructure with a new ferrite-martensite-tempered martensite and retained austenite microstructure. The new microstructure exhibited a somewhat lower strength but much high general and local formabilities. In this thesis, both the physical and mechanical metallurgy of these steels and processes will be discussed. This research has shown that simple compositions and processes can result in DP steels with so-called Generation III properties.

Superplastic Aluminum Evaluation

DTIC Science & Technology

1981-06-01

Gold coated. 450 Lilt to electron beam ...................... ............... 111 16 Scanning electron micrograph of a cross section through a cavity... Gold coated. 450 tilt to electron beam ............. ...... .. ... 113 17 Typical EDAX spectra from (a) dark, angular, loose particles ((Fe,Cr)3SiAll...with atmospheric water vapor to form aluminum oxide and hydrogen. The hydrogen (already in monoatomic form) is very rapidly dissolved by the liquid

Superplastic Forming of Duplex Stainless Steel for Aerospace Part

NASA Astrophysics Data System (ADS)

Lee, Ho-Sung; Yoon, Jong-Hoon; Yoo, Joon-Tae; Yi, Young-Moo

2011-08-01

In this study, the high temperature forming behavior of duplex stainless steel has been characterized and the outer shell of a combustion chamber was fabricated with pressure difference of hot gas. It consists of two parts which are the outer skin made of stainless steel to sustain the internal pressure and the inner shell made of copper alloy for regenerative cooling channels. Two outer skins partitioned to half with respect to the symmetric axis was prepared by hot gas forming process with a maximum pressure of 7 MPa following to FEM analysis. For inner layer, copper alloy was machined for cooling channels and then placed in the gas pressure welding fixture. It is shown that the optimum condition of gas pressure welding is 7 MPa at 890 °C, for one hour. EDX analysis and scanning electron microscope micrograph confirm the atomic diffusion process is observed at the interface and copper atoms diffuse into steel, while iron and chrome atoms diffuse into copper. The result shows that the manufacturing method with superplastic forming and gas pressure welding of steel and copper alloy has been successful for near net shape manufacturing of scaled combustion chamber of launch vehicle.

Superplastic behavior of two ultrahigh boron steels

NASA Astrophysics Data System (ADS)

Jiménez, J. A.; González-Doncel, G.; Acosta, P.; Ruano, O. A.

1994-06-01

The high-temperature deformation behavior of two ultrahigh boron steels containing 2.2 pct and 4.9 pct B was investigated. Both alloys were processed via powder metallurgy involving gas atomization and hot isostatic pressing (hipping) at various temperatures. After hipping at 700 °C, the Fe-2.2 pct B alloy showed a fine microstructure consisting of l- µm grains and small elongated borides (less than 1 µm) . At 1100 °C, a coarser microstructure with rounded borides was formed. This alloy was superplastic at 850 °C with stress exponents of about two and tensile elongations as high as 435 pct. The microstructure of the Fe-4.9 pct B alloy was similar to that of the Fe-2.2 pct B alloy showing, in addition, coarse borides. This alloy also showed low stress exponent values but lacked high tensile elongation (less than 65 pct), which was attributed to the presence of stress accumulation at the interface between the matrix and the large borides. A change in the activation energy value at the α-γ transformation temperature was seen in the Fe-2.2 pct B alloy. The plastic flow data were in agreement with grain boundary sliding and slip creep models.

Failure prediction during backward flow forming of Ti6Al4V alloy

NASA Astrophysics Data System (ADS)

Singh, Abhishek Kumar; Narasimhan, K.; Singh, Ramesh

2018-05-01

The Flow forming process is a tube spinning process where the thickness of a tube is reduced with the help of spinning roller/s by keeping the internal diameter unchanged. A 3-D Finite element model for the flow-formability test has been developed by using Abaqus/explicit software. A coupled damage criterion based on continuum damage mechanics (CDM) has been studied in this research. The damage model is introduced by using FORTRAN based VUMAT subroutine which is developed through a stress integration algorithm. Further, the effect of reduction angle, friction coefficient, and coolant heat transfer coefficient on fracture has been studied. The results show that the formability improves with increase in reduction angle. Both, equivalent plastic strain and damage variable increases from inner to outer surface of flow formed tube.

Damage percolation during stretch flange forming of aluminum alloy sheet

NASA Astrophysics Data System (ADS)

Chen, Zengtao; Worswick, Michael J.; Keith Pilkey, A.; Lloyd, David J.

2005-12-01

A multi-scale finite element (FE)-damage percolation model was employed to simulate stretch flange forming of aluminum alloys AA5182 and AA5754. Material softening and strain gradients were captured using a Gurson-based FE model. FE results were then fed into the so-called damage percolation code, from which the damage development was modelled within measured microstructures. The formability of the stretch flange samples was predicted based upon the onset of catastrophic failure triggered by profuse void coalescence within the measured second-phase particle field. Damage development is quantified in terms of crack and void areal fractions, and compared to metallographic results obtained from interrupted stretch flange specimens. Parametric study is conducted on the effect of void nucleation strain in the prediction of formability of stretch flanges to "calibrate" proper nucleation strains for both alloys.

Conditioning of material properties by micro rotary swaging

NASA Astrophysics Data System (ADS)

Ishkina, Svetlana; Schenck, Christian; Kuhfuss, Bernd

2018-05-01

Cold forming initiates a change of the material properties like flow stress and hardness. Due to work hardening and the accompanied loss of formability some intermediate heat treatment may become necessary in multi-stage forming processes. One possibility to avoid this heat treatment is to adjust the forming characteristics in terms of flow stress and formability by rotary swaging. This process is particularly suitable not only for producing of the target geometry but also for modifying of the material properties during the process and thus, rotary swaging can prepare the parts for further forming, such as extrusion. In this contribution, the process chain "rotary swaging - extrusion" for austenite stainless steel AISI304 was investigated. The forming characteristics of the semi-finished products for the extrusion were influenced by the previous swaging process. The conditioning by changing of the microstructure, the work hardening and the geometry of the processed wires was achieved by the process design. For this purpose, the geometry of the swaging dies, the feeding velocity as well as the process kinematics (eccentric swaging) and a stroke following angle Δɸ were varied. In particular, the novel geometry of the swaging dies with extraordinary sloped faces generated a non-symmetric material flow with severe shear deformation and thus an extreme change of the microstructure. The required forming force of the following extrusion process reflected the range of achievable conditioning. The micro rotary swaging process positively improved the formability of AISI304 by work softening.

Effect of Local Post Weld Heat Treatment on Tensile Properties in Friction Stir Welded 2219-O Al Alloy

NASA Astrophysics Data System (ADS)

Chu, Guannan; Sun, Lei; Lin, Caiyuan; Lin, Yanli

2017-11-01

To improve the formability of the aluminum alloy welds and overcome the size limitation of the bulk post weld heat treatment (BPWHT) on large size friction stir welded joints, a local post weld heat treatment method (LPWHT) was proposed. In this method, the resistance heating as the moving heat source is adopted to only heat the weld seam. The temperature field of LPWHT and its influence on the mechanical properties and formability of FSW 2219-O Al alloy joints was investigated. The evaluation of the tensile properties of FSW samples was also examined by mapping the global and local strain distribution using the digital image correlation methodology. The results indicated that the formability was improved greatly after LPWHT, while the hardness distribution of the FSW joint was homogenized. The maximum elongation can reach 1.4 times that of as-welded joints with increase the strength and the strain of the nugget zone increased from 3 to 8% when annealing at 300 °C. The heterogeneity on the tensile deformation of the as-welded joints was improved by the nugget zone showing large local strain value and the reason was given according to the dimple fracture characteristics at different annealing temperatures. The tensile strength and elongation of LPWHT can reach 93.3 and 96.1% of the BPWHT, respectively. Thus, the LPWHT can be advantageous compared to the BPWHT for large size welds.

Experimental and Numerical Studies on Isothermal and Non-isothermal Deep Drawing of IS 513 CR3 Steel Sheets

NASA Astrophysics Data System (ADS)

Mayavan, T.; Karthikeyan, L.; Senthilkumar, V. S.

2016-11-01

The present work aims to investigate the effects of the temperature gradient developed within the tool profiles on the formability of IS 513 CR3-grade steel sheets using the cup drawing test. The deformation characteristics of steel sheets were analyzed by comparing the thicknesses in various regions of the formed cup and also the limiting drawing ratios (LDR). Finite element simulations were carried out to predict the behavior of the steel sheets in isothermal and non-isothermal forming using Abaqus/Standard 6.12-1. An analytical model created by Kim was used to validate the experimental and finite element analysis (FEA) results on identical process parameters. Both the FEA and analytical modeling results showed that formability improvement is possible in warm forming; the findings are in good agreement with the experimental results in determining the locations and values of excessive thinning. The results also indicated that formability improvement cannot be achieved by keeping the tooling temperature at the same level. The LDR increased by around 9.5% in isothermal forming and by 19% in non-isothermal forming (with the punch maintained at a lower temperature compared with the die and blank holder). In addition, the fractured surfaces of unsuccessfully formed samples were analyzed using scanning electron microscopy. Metallographic investigations confirmed that the fracture mechanism during the forming of IS 513 CR3-grade steel sheets depends on the brittleness, strain hardening value, forming temperature, and magnitude of stresses developed.

A Comparative Study on Formability of the Third-Generation Automotive Medium-Mn Steel and 22MnB5 Steel

NASA Astrophysics Data System (ADS)

Zheng, Guojun; Li, Xiaodong; Chang, Ying; Wang, Cunyu; Dong, Han

2018-02-01

Third-generation advanced automotive medium-Mn steel, which can replace 22MnB5 steel, was newly developed to improve the lightweight and crashworthiness of automobile. Studies on the formability and simulation method of medium-Mn steel have just been initiated. In this study, finite element simulation models of square-cup deep drawing were established based on various material property experiments and validated by experiments. The effects of blank holder force (BHF), fillet radii of tools (die and punch) on the maximum drawing depth (MDD), thickness distribution of the formed products, and the microstructure before and after forming were investigated and compared with those on 22MnB5 steel. Results show that the MDD of the two steels decreased with increased BHF but increased with the fillet radius of punch; however, the fillet radius of die showed no significant effect on the MDD for both steels. Compared with hot-formed 22MnB5 steel, the martensitic transformation of the hot-formed medium-Mn steel is rarely influenced by the process parameters; thus, it holds the complete, fine-grained, and uniform martensitic microstructure. Moreover, the medium-Mn has better formability, lower initial blank temperature, and smaller impact of BHF and fillet radius of tools on the hot-formed product. Thus, a theoretical basis for the replacement of 22MnB5 steel by medium-Mn steel in hot forming process is provided.

Advanced bulk processing of lightweight materials for utilization in the transportation sector

NASA Astrophysics Data System (ADS)

Milner, Justin L.

The overall objective of this research is to develop the microstructure of metallic lightweight materials via multiple advanced processing techniques with potentials for industrial utilization on a large scale to meet the demands of the aerospace and automotive sectors. This work focused on (i) refining the grain structure to increase the strength, (ii) controlling the texture to increase formability and (iii) directly reducing processing/production cost of lightweight material components. Advanced processing is conducted on a bulk scale by several severe plastic deformation techniques including: accumulative roll bonding, isolated shear rolling and friction stir processing to achieve the multiple targets of this research. Development and validation of the processing techniques is achieved through wide-ranging experiments along with detailed mechanical and microstructural examination of the processed material. On a broad level, this research will make advancements in processing of bulk lightweight materials facilitating industrial-scale implementation. Where accumulative roll bonding and isolated shear rolling, currently feasible on an industrial scale, processes bulk sheet materials capable of replacing more expensive grades of alloys and enabling low-temperature and high-strain-rate formability. Furthermore, friction stir processing to manufacture lightweight tubes, made from magnesium alloys, has the potential to increase the utilization of these materials in the automotive and aerospace sectors for high strength - high formability applications. With the increased utilization of these advanced processing techniques will significantly reduce the cost associated with lightweight materials for many applications in the transportation sectors.

Effect of hot working on the damping capacity and mechanical properties of AZ31 magnesium alloy

NASA Astrophysics Data System (ADS)

Lee, K.; Kang, C.; Kim, K.

2015-04-01

Magnesium alloys have received much attention for their lightweight and other excellent properties, such as low density, high specific strength, and good castability, for use in several industrial and commercial applications. However, both magnesium and its alloys show limited room-temperature formability owing to the limited number of slip systems associated with their hexagonal close-packed crystal structure. It is well known that crystallographic texture plays an important role in both plastic deformation and macroscopic anisotropy of magnesium alloys. Many authors have concentrated on improving the room- temperature formability of Mg alloys. However, despite having a lot of excellent properties in magnesium alloy, the study for various properties of magnesium alloy have not been clarified enough yet. Mg alloys are known to have a good damping capacity compared to other known metals and their alloys. Also, the damping properties of metals are generally recognized to be dependent on microstructural factors such as grain size and texture. However, there are very few studies on the relationship between the damping capacity and texture of Magnesium alloys. Therefore, in this study, specimens of the AZ31 magnesium alloy, were processed by hot working, and their texture and damping property investigated. A 60 mm × 60 mm × 40 mm rectangular plate was cut out by machining an ingot of AZ31 magnesium alloy (Mg-3Al-1Zn in mass%), and rolling was carried out at 673 K to a rolling reduction of 30%. Then, heat treatment was carried out at temperatures in the range of 573-723 K for durations in the range of 30-180 min. The samples were immediately quenched in oil after heat treatment to prevent any change in the microstructure. Texture was evaluated on the compression planes by the Schulz reflection method using nickel-filtered Cu Kα radiation. Electron backscatter diffraction measurements were conducted to observe the spatial distribution of various orientations. Specimens for damping capacity measurements were machined from the rolled specimen, to have a length of 120 mm, width of 20 mm, and thickness of 1 mm. The damping capacity was measured with a flexural internal friction measurement machine at room temperature. It was found that the damping capacity increases with both increasing heat-treatment temperature and time, due to grain growth and the increased pole densities of textures.

Identification of Deformation Mechanisms During Bi-Axial Straining of Superplastic AA5083 Material

DTIC Science & Technology

2004-06-01

equiaxed grain structure in FSS along with the prevalence of high - energy boundaries accommodates sliding under the proper shearing conditions. Figure...by a randomized texture and a higher concentration of high disorientation angles. Dislocation creep, which dominates at higher strain rates, is...concentration of high disorientation angles. Dislocation creep, which dominates at higher strain rates, is characterized by fiber texture formation

Mechanisms of Superplastic Deformation of Nanocrystalline Silicon Carbide Ceramics

DTIC Science & Technology

2012-08-01

These included the following: standard hot isostatic pressing (HIP), spark plasma sintering , ultra-high pressure HIP, and a multianvil pressure...96.8 2270 Multianvil apparatus 1200 3000 94.8 1130 Note: SPS = spark plasma sintering . 2 Figure 1. Ultra-high pressure HIP; 1600 °C, 980...strain rate sensitivity and flow stress. 15. SUBJECT TERMS silicon carbide, nanostructure, sintering , hot isostatic pressing, hardness 16. SECURITY

3D Printing Factors Important for the Fabrication of Polyvinylalcohol Filament-Based Tablets.

PubMed

Tagami, Tatsuaki; Fukushige, Kaori; Ogawa, Emi; Hayashi, Naomi; Ozeki, Tetsuya

2017-01-01

Three-dimensional (3D) printers have been applied in many fields, including engineering and the medical sciences. In the pharmaceutical field, approval of the first 3D-printed tablet by the U.S. Food and Drug Administration in 2015 has attracted interest in the manufacture of tablets and drugs by 3D printing techniques as a means of delivering tailor-made drugs in the future. In current study, polyvinylalcohol (PVA)-based tablets were prepared using a fused-deposition-modeling-type 3D printer and the effect of 3D printing conditions on tablet production was investigated. Curcumin, a model drug/fluorescent marker, was loaded into PVA-filament. We found that several printing parameters, such as the rate of extruding PVA (flow rate), can affect the formability of the resulting PVA-tablets. The 3D-printing temperature is controlled by heating the print nozzle and was shown to affect the color of the tablets and their curcumin content. PVA-based infilled tablets with different densities were prepared by changing the fill density as a printing parameter. Tablets with lower fill density floated in an aqueous solution and their curcumin content tended to dissolve faster. These findings will be useful in developing drug-loaded PVA-based 3D objects and other polymer-based articles prepared using fused-deposition-modeling-type 3D printers.

Grain neighbour effects on twin transmission in hexagonal close-packed materials

DOE PAGES

Arul Kumar, Mariyappan; Beyerlein, Irene Jane; McCabe, Rodney James; ...

2016-12-19

Materials with a hexagonal close-packed (hcp) crystal structure such as Mg, Ti and Zr are being used in the transportation, aerospace and nuclear industry, respectively. Material strength and formability are critical qualities for shaping these materials into parts and a pervasive deformation mechanism that significantly affects their formability is deformation twinning. The interaction between grain boundaries and twins has an important influence on the deformation behaviour and fracture of hcp metals. Here, statistical analysis of large data sets reveals that whether twins transmit across grain boundaries depends not only on crystallography but also strongly on the anisotropy in crystallographic slip.more » As a result, we show that increases in crystal plastic anisotropy enhance the probability of twin transmission by comparing the relative ease of twin transmission in hcp materials such as Mg, Zr and Ti.« less

Effect of Chemical Treatments on Flax Fibre Reinforced Polypropylene Composites on Tensile and Dome Forming Behaviour

PubMed Central

Wang, Wentian; Lowe, Adrian; Kalyanasundaram, Shankar

2015-01-01

Tensile tests were performed on two different natural fibre composites (same constituent material, similar fibre fraction and thickness but different weave structure) to determine changes in mechanical properties caused by various aqueous chemical treatments and whether any permanent changes remain on drying. Scanning electronic microscopic examinations suggested that flax fibres and the flax/polypropylene interface were affected by the treatments resulting in tensile property variations. The ductility of natural fibre composites was improved significantly under wet condition and mechanical properties (elongation-to-failure, stiffness and strength) can almost retain back to pre-treated levels when dried from wet condition. Preheating is usually required to improve the formability of material in rapid forming, and the chemical treatments performed in this study were far more effective than preheating. The major breakthrough in improving the formability of natural fibre composites can aid in rapid forming of this class of material system. PMID:25789505

Deformation and recrystallization behavior of super high-purity niobium for SRF cavity

NASA Astrophysics Data System (ADS)

Yamaguchi, Y.; Doryo, H.; Yuasa, M.; Miyamoto, H.; Yamanaka, M.

2017-05-01

Deformation and recyrstallization behavior of pure niobium was investigated in order to clarify the origin of its low hydro-formability despite of its high ductility comparable with pure iron. It was found that pure niobium exhibits lower strain hardening in cold rolling compared with pure iron. Furthermore, in post-deformation annealing, the hardness of niobium decreased monotonously with an increase of temperature, and the typical sharp drop by recrystallization was not evident. This softening behavior was contrasted with the high-purity iron. It is suggested that niobium exhibit the so-called in-situ recrystallization possibly because of low elastic modulus and low accumulative plastic strain energy in spite of high melting temperature. The low hydro-formability of pure niobium sheets or tubes is caused by its low strain hardening and its unique plastic anisotropy which is associated with this recovered residual rolled texture.

Prediction Of Formability In Sheet Metal Forming Processes Using A Local Damage Model

NASA Astrophysics Data System (ADS)

Teixeira, P.; Santos, Abel; César Sá, J.; Andrade Pires, F.; Barata da Rocha, A.

2007-05-01

The formability in sheet metal forming processes is mainly conditioned by ductile fracture resulting from geometric instabilities due to necking and strain localization. The macroscopic collapse associated with ductile failure is a result of internal degradation described throughout metallographic observations by the nucleation, growth and coalescence of voids and micro-cracks. Damage influences and is influenced by plastic deformation and therefore these two dissipative phenomena should be coupled at the constitutive level. In this contribution, Lemaitre's ductile damage model is coupled with Hill's orthotropic plasticity criterion. The coupling between damaging and material behavior is accounted for within the framework of Continuum Damage Mechanics (CDM). The resulting constitutive equations are implemented in the Abaqus/Explicit code, for the prediction of fracture onset in sheet metal forming processes. The damage evolution law takes into account the important effect of micro-crack closure, which dramatically decreases the rate of damage growth under compressive paths.

Formability analysis of aluminum alloy sheets at elevated temperatures with numerical simulation based on the M-K method

DOE Office of Scientific and Technical Information (OSTI.GOV)

Bagheriasl, Reza; Ghavam, Kamyar; Worswick, Michael

2011-05-04

The effect of temperature on formability of aluminum alloy sheet is studied by developing the Forming Limit Diagrams, FLD, for aluminum alloy 3000-series using the Marciniak and Kuczynski technique by numerical simulation. The numerical model is conducted in LS-DYNA and incorporates the Barlat's YLD2000 anisotropic yield function and the temperature dependant Bergstrom hardening law. Three different temperatures; room temperature, 250 deg. C and 300 deg. C, are studied. For each temperature case, various loading conditions are applied to the M-K defect model. The effect of the material anisotropy is considered by varying the defect angle. A simplified failure criterion ismore » used to predict the onset of necking. Minor and major strains are obtained from the simulations and plotted for each temperature level. It is demonstrated that temperature improves the forming limit of aluminum 3000-series alloy sheet.« less

Application technologies for effective utilization of advanced high strength steel sheets

DOE Office of Scientific and Technical Information (OSTI.GOV)

Suehiro, Masayoshi, E-mail: suehiro.kp5.masayoshi@jp.nssmc.com

Recently, application of high strength steel sheets for automobiles has increased in order to meet a demand of light weighting of automobiles to reduce a carbon footprint while satisfying collision safety. The formability of steel sheets generally decreases with the increase in strength. Fracture and wrinkles tend to occur easily during forming. The springback phenomenon is also one of the issues which we should cope with, because it makes it difficult to obtain the desired shape after forming. Advanced high strength steel sheets with high formability have been developed in order to overcome these issues, and at the same timemore » application technologies have been developed for their effective utilization. These sheets are normally used for cold forming. As a different type of forming, hot forming technique has been developed in order to produce parts with ultra high strength. In this report, technologies developed at NSSMC in this field will be introduced.« less

Process Mechanics Analysis in Single Point Incremental Forming

NASA Astrophysics Data System (ADS)

Ambrogio, G.; Filice, L.; Fratini, L.; Micari, F.

2004-06-01

The request of highly differentiated products and the need of process flexibility have brought the researchers to focus the attention on innovative sheet forming processes. Industrial application of conventional processes is, in fact, economically convenient just for large scale productions; furthermore conventional processes do not allow to fully satisfy the mentioned demand of flexibility. In this contest, single point incremental forming (SPIF) is an innovative and flexible answer to market requests. The process is characterized by a peculiar process mechanics, being the sheet plastically deformed only through a localised stretching mechanism. Some recent experimental studies have shown that SPIF permits a relevant increase of formability limits, just as a consequence of the peculiar deformation mechanics. The research here addressed is focused on the theoretical investigation of process mechanics; the aim was to achieve a deeper understanding of basic phenomena involved in SPIF which justify the above mentioned formability enhancing.

Formability analysis of aluminum alloys through deep drawing process

NASA Astrophysics Data System (ADS)

Pranavi, U.; Janaki Ramulu, Perumalla; Chandramouli, Ch; Govardhan, Dasari; Prasad, PVS. Ram

2016-09-01

Deep drawing process is a significant metal forming process used in the sheet metal forming operations. From this process complex shapes can be manufactured with fewer defects. Deep drawing process has different effectible process parameters from which an optimum level of parameters should be identified so that an efficient final product with required mechanical properties will be obtained. The present work is to evaluate the formability of Aluminum alloy sheets using deep drawing process. In which effects of punch radius, lubricating conditions, die radius, and blank holding forces on deep drawing process observed for AA 6061 aluminum alloy sheet of 2 mm thickness. The numerical simulations are performed for deep drawing of square cups using three levels of aforesaid parameters like lubricating conditions and blank holding forces and two levels of punch radii and die radii. For numerical simulation a commercial FEM code is used in which Hollomon's power law and Hill's 1948 yield criterions are implemented. The deep drawing setup used in the FEM code is modeled using a CAD tool by considering the modeling requirements from the literature. Two different strain paths (150x150mm and 200x200mm) are simulated. Punch forces, thickness distributions and dome heights are evaluated for all the conditions. In addition failure initiation and propagation is also observed. From the results, by increasing the coefficient of friction and blank holding force, punch force, thickness distribution and dome height variations are observed. The comparison has done and the optimistic parameters were suggested from the results. From this work one can predict the formability for different strain paths without experimentation.

Mitigating Abnormal Grain Growth for Friction Stir Welded Al-Li 2195 Spun Formed Domes

NASA Technical Reports Server (NTRS)

Chen, Po-Shou; Russell, Carolyn

2012-01-01

Formability and abnormal grain growth (AGG) are the two major issues that have been encountered for Al alloy spun formed dome development using friction stir welded blanks. Material properties that have significant influence on the formability include forming range and strain hardening exponent. In this study, tensile tests were performed for two 2195 friction stir weld parameter sets at 400 F to study the effects of post weld anneal on the forming range and strain hardening exponent. It was found that the formability can be enhanced by applying a newly developed post weld anneal to heat treat the friction stir welded panels. This new post weld anneal leads to a higher forming range and much improved strain hardening exponent. AGG in the weld nugget is known to cause a significant reduction of ductility and fracture toughness. This study also investigated how AGG may be influenced by the heating rate to the solution heat treatment temperature. After post-weld annealing, friction stir welds were strained to 15% and 39% by compression at 400 F before they were subjected to SHT at 950 F for 1 hour. Salt bath SHT is very effective in reducing the grain size as it helps arrest the onset of AGG and promote normal recrystallization and grain growth. However, heat treating a 18 ft dome using a salt bath is not practical. Efforts are continuing at Marshall Space Flight Center to identify the welding parameters and heat treating parameters that can help mitigate the AGG in the friction stir welds.

Experimental and Numerical Investigations of Constraint Effect on Deformation Behavior of Tailor-Welded Blanks

NASA Astrophysics Data System (ADS)

Li, Yanhua; Lin, Jianping

2015-08-01

Tailor-welded blanks (TWBs) have been considered as a productive sheet forming method in automotive industries. However, formability of TWBs is reduced due to different properties or thicknesses of the blanks and is a challenge for manufacturing designers. The plastic capacity of TWBs is decreased even when the material and thickness are the same. The constraint effect of the laser weld (including weld and heat-affected zone) material in the forming process of similar TWBs is a key problem to be solved in the research, development and application of thin-sheet TWBs. In this paper, uniaxial tensile tests with full-field strain measurement by digital image correlation and Erichsen tests are performed to investigate the constraint effect on deformation behavior and explore the mechanism of decreasing formability of similar TWBs. In addition, finite element models are conducted under ABAQUS code to further reveal the phenomenal behavior of the constraint effect. The results of the base material and welded blanks are compared for characterizing the differences. Furthermore, in order to better understand this mechanism, theoretical and numerical investigations are employed and compared to interpret the constraint effect of laser weld on the deformation behavior of TWBs. An index is proposed to quantify the constraint effect. Results show that the constraint effect of laser weld appears in both stretch forming and drawing of TWBs. Strain paths are approaching the plane strain condition as compared to the monolithic blank due to the constraint effect. Constraint effect is a major factor affecting the formability of TWBs when the failure occurs away from the weld seam.

Effect of the Process Parameters on the Formability, Microstructure, and Mechanical Properties of Thin Plates Fabricated by Rheology Forging Process with Electromagnetic Stirring Method

NASA Astrophysics Data System (ADS)

Jin, Chul Kyu; Jang, Chang Hyun; Kang, Chung Gil

2014-01-01

A thin plate (150 × 150 × 1.2 mm) with embedded corrugation is fabricated using the rheoforming method. Semisolid slurry is created using the electromagnetic stirring (EMS) system, and the thin plate is made with the forging die at the 200-ton hydraulic press. The cross sections and microstructures of the slurry with and without stirring are examined. To investigate the effect of the process parameters on the formability, microstructure, and mechanical properties of thin plate the slurry is subjected to 16 types of condition for the forging experiment. The 16 types included the following conditions: Whether the EMS is applied or not, three fractions of the solid phase at 35, 45 and 55 pct; two compression velocities at 30 and 300 mm s-1; and four different compression pressures—100, 150, 200 and 250 MPa. The thin plate's formability is enhanced at higher punch velocity for compressing the slurry, and fine solid particles are uniformly distributed, which in turn, enhances the plate's mechanical properties. The pressure between 150 and 200 MPa is an appropriate condition to form thin plates. A thin plate without defects can be created when the slurry at 35 pct of the solid fraction (f s) was applied at the compression velocity of 300 mm s-1 and 150 MPa of pressure. The surface state of thin plate is excellent with 220 MPa of tensile strength and 13.5 pct of elongation. The primary particles are fine over the entire plate, and there are no liquid segregation-related defects.

Novel Routes for Sintering of Ultra-high Temperature Ceramics and their Properties

DTIC Science & Technology

2014-10-31

UHTCs charge (zirconium and hafnium borides , SiC) with additives (chromium carbide, nickel, chromium, etc.), which activate sintering process, is...temperature phases in a form of carboborides of zirconium and bi borides of zirconium or chromium. Elevation of densification rate of sintered borides is...superplasticity under the slip mechanism of zirconium boride and silica carbide grains on grain boundary interlayers with nanocrystalline grains of carbon

JPRS Report, Science & Technology, Japan, 28th Ceramics Science Discussion

DTIC Science & Technology

1990-11-13

U non doped "5 Ag powder A 60 120 180 140 300 Temperature (K) Figure 1. Plots or Resistivity Vs. Temperature for YBa 2 Cu 30Y to Which Different...Yasuharu Kodama, et al.] ........................ 13 -a - Superplasticity of Hydroxyapatite [Fumihiro Wakai, Yasuharu Kodama, et al...67 Synthesis of Ag -Added Bi-Pb-Ca-Cu-O Powder by Spray Drying, Superconductivity of Powder [Hiroko Higuma, Mitsunobu Wakata, et al

Diffusion bonding aeroengine components

NASA Astrophysics Data System (ADS)

Fitzpatrick, G. A.; Broughton, T.

1988-10-01

The use of diffusion bonding processes at Rolls-Royce for the manufacture of titanium-alloy aircraft engine components and structures is described. A liquid-phase diffusion bonding process called activated diffusion bonding has been developed for the manufacture of the hollow titanium wide chord fan blade. In addition, solid-state diffusion bonding is being used in the manufacture of hollow vane/blade airfoil constructions mainly in conjunction with superplastic forming and hot forming techniques.

Superplasticity. Revision

DTIC Science & Technology

1989-09-01

angle to the applied tension and failure rapidly follows, as the volume of metal now deforming is small. Local necking Contributes virtually nothing...into components. It is thought that the 9 phase may be responsible for grain refinement, but it may be due to minute traces of oxide on the original...order to minimize oxidation and related detrimental surface degradation due to the reactivity of titanium. The use of such protective gases is not

Future requirements for advanced materials

NASA Technical Reports Server (NTRS)

Olstad, W. B.

1980-01-01

Recent advances and future trends in aerospace materials technology are reviewed with reference to metal alloys, high-temperature composites and adhesives, tungsten fiber-reinforced superalloys, hybrid materials, ceramics, new ablative materials, such as carbon-carbon composite and silica tiles used in the Shuttle Orbiter. The technologies of powder metallurgy coupled with hot isostatic pressing, near net forging, complex large shape casting, chopped fiber molding, superplastic forming, and computer-aided design and manufacture are emphasized.

High Temperature Deformation of Twin-Roll Cast Al-Mn-Based Alloys after Equal Channel Angular Pressing.

PubMed

Málek, Přemysl; Šlapáková Poková, Michaela; Cieslar, Miroslav

2015-11-12

Twin roll cast Al-Mn- and Al-Mn-Zr-based alloys were subjected to four passes of equal channel angular pressing. The resulting grain size of 400 nm contributes to a significant strengthening at room temperature. This microstructure is not fully stable at elevated temperatures and recrystallization and vast grain growth occur at temperatures between 350 and 450 °C. The onset of these microstructure changes depends on chemical and phase composition. Better stability is observed in the Al-Mn-Zr-based alloy. High temperature tensile tests reveal that equal channel angular pressing results in a softening of all studied materials at high temperatures. This can be explained by an active role of grain boundaries in the deformation process. The maximum values of ductility and strain rate sensitivity parameter m found in the Al-Mn-Zr-based alloy are below the bottom limit of superplasticity (155%, m = 0.25). However, some features typical for superplastic behavior were observed-the strain rate dependence of the parameter m , the strengthening with increasing grain size, and the fracture by diffuse necking. Grain boundary sliding is believed to contribute partially to the overall strain in specimens where the grain size remained in the microcrystalline range.

Study of the properties and the choice of alloys for bladed disks (blisks) and a method for their joining

NASA Astrophysics Data System (ADS)

Povarova, K. B.; Valitov, V. A.; Obsepyan, S. V.; Drozdov, A. A.; Bazyleva, O. A.; Valitova, E. V.

2014-09-01

The choice of materials for the bladed disks (blisks) that are intended for next-generation aviation gas turbine engines is grounded. As blade materials, single crystals of light heterophase γ' + γ VKNA-type alloys based on the γ'(Ni3Al) intermetallic compound with an ordered structure are proposed. The choice of novel deformable EP975-type nickel superalloys, which are intended for operation at 800-850°C, as the disk material is grounded. It is shown that the most effective method for forming one-piece joints of an Ni3Al-based alloy and a high-alloy EP975-type nickel superalloy is the new process of solid-phase pressure welding under conditions of high-temperature superplasticity. Solid-phase joints are formed for heterophase Ni3Al-based alloy single crystals and deformable EK61 and EP975 nickel alloys. The gradient structures in the zone of the solid-phase joints that form under the conditions of low- and high-temperature superplasticity at homologous temperatures of ˜0.6 T m and 0.9 T m are studied. The character and direction of the diffusion processes at the joint of an intermetallic alloy single crystal and a deformable polycrystalline alloy are determined.

Thermal Microstructural Stability of AZ31 Magnesium after Severe Plastic Deformation

DOE Office of Scientific and Technical Information (OSTI.GOV)

Young, John P.; Askari, Hesam A.; Hovanski, Yuri

2015-03-01

Both equal channel angular pressing and friction stir processing have the ability to refine the grain size of twin roll cast AZ31 magnesium and potentially improve its superplastic properties. This work used isochronal and isothermal heat treatments to investigate the microstructural stability of twin roll cast, equal channel angular pressed and friction stir processed AZ31 magnesium. For both heat treatment conditions, it was found that the twin roll casted and equal channel angular pressed materials were more stable than the friction stir processed material. Calculations of the grain growth kinetics showed that severe plastic deformation processing decreased the activation energymore » for grain boundary motion with the equal channel angular pressed material having the greatest Q value of the severely plastically deformed materials and that increasing the tool travel speed of the friction stir processed material improved microstructural stability. The Hollomon-Jaffe parameter was found to be an accurate means of identifying the annealing conditions that will result in substantial grain growth and loss of potential superplastic properties in the severely plastically deformed materials. In addition, Humphreys’s model of cellular microstructural stability accurately predicted the relative microstructural stability of the severely plastically deformed materials and with some modification, closely predicted the maximum grain size ratio achieved by the severely plastically deformed materials.« less

High Temperature Deformation of Twin-Roll Cast Al-Mn-Based Alloys after Equal Channel Angular Pressing

PubMed Central

Málek, Přemysl; Šlapáková Poková, Michaela; Cieslar, Miroslav

2015-01-01

Twin roll cast Al-Mn- and Al-Mn-Zr-based alloys were subjected to four passes of equal channel angular pressing. The resulting grain size of 400 nm contributes to a significant strengthening at room temperature. This microstructure is not fully stable at elevated temperatures and recrystallization and vast grain growth occur at temperatures between 350 and 450 °C. The onset of these microstructure changes depends on chemical and phase composition. Better stability is observed in the Al-Mn-Zr-based alloy. High temperature tensile tests reveal that equal channel angular pressing results in a softening of all studied materials at high temperatures. This can be explained by an active role of grain boundaries in the deformation process. The maximum values of ductility and strain rate sensitivity parameter m found in the Al-Mn-Zr-based alloy are below the bottom limit of superplasticity (155%, m = 0.25). However, some features typical for superplastic behavior were observed—the strain rate dependence of the parameter m, the strengthening with increasing grain size, and the fracture by diffuse necking. Grain boundary sliding is believed to contribute partially to the overall strain in specimens where the grain size remained in the microcrystalline range. PMID:28793667

77 FR 45600 - Certain New Chemicals; Receipt and Status Information

Federal Register 2010, 2011, 2012, 2013, 2014

2012-08-01

...-0373...... 05/25/2012 08/22/2012 CBI (G) Abrasion (G) 1,4- resistant, butanediol, formable dual.......... 06/13/2012 06/11/2012 (G) Aliphatic epoxy acrylate. P-12-0019....... 06/08/2012 06/05/2012 (S) Starch...

Ultrahigh Carbon Steel.

DTIC Science & Technology

1984-10-01

The unique mechanical properties achieved in UHC steels are due to the presence of micron-size ferrite grains and ultrafine spheroidized carbides. SN...unique mechanical properties achieved in UHC [0 steels are due to the presence of micron-size ferrite grains and ultrafine spheroidized carbides. 0... steel is that it has a low resistance to plastic flow upon deformation in the superplastic range at low strain rates (e.g., 2000 psi at 4 1041 e 10 s

Effect of process parameters on formability of laser melting deposited 12CrNi2 alloy steel

NASA Astrophysics Data System (ADS)

Peng, Qian; Dong, Shiyun; Kang, Xueliang; Yan, Shixing; Men, Ping

2018-03-01

As a new rapid prototyping technology, the laser melting deposition technology not only has the advantages of fast forming, high efficiency, but also free control in the design and production chain. Therefore, it has drawn extensive attention from community.With the continuous improvement of steel performance requirements, high performance low-carbon alloy steel is gradually integrated into high-tech fields such as aerospace, high-speed train and armored equipment.However, it is necessary to further explore and optimize the difficult process of laser melting deposited alloy steel parts to achieve the performance and shape control.This article took the orthogonal experiment on alloy steel powder by laser melting deposition ,and revealed the influence rule of the laser power, scanning speed, powder gas flow on the quality of the sample than the dilution rate, surface morphology and microstructure analysis were carried out.Finally, under the optimum technological parameters, the Excellent surface quality of the alloy steel forming part with high density, no pore and cracks was obtained.

Performance evaluation of concrete bridge decks reinforced with MMFX and SSC rebars.

DOT National Transportation Integrated Search

2006-01-01

This report investigates the performance of bridge decks reinforced with stainless steel clad (SSC) and micro-composite multistructural formable steel (MMFX) rebars. The two-span Galloway Road Bridge on route CR5218 over North Elkhorn Creek in Scott ...

Advancing density functional theory to finite temperatures: methods and applications in steel design

NASA Astrophysics Data System (ADS)

Hickel, T.; Grabowski, B.; Körmann, F.; Neugebauer, J.

2012-02-01

The performance of materials such as steels, their high strength and formability, is based on an impressive variety of competing mechanisms on the microscopic/atomic scale (e.g. dislocation gliding, solid solution hardening, mechanical twinning or structural phase transformations). Whereas many of the currently available concepts to describe these mechanisms are based on empirical and experimental data, it becomes more and more apparent that further improvement of materials needs to be based on a more fundamental level. Recent progress for methods based on density functional theory (DFT) now makes the exploration of chemical trends, the determination of parameters for phenomenological models and the identification of new routes for the optimization of steel properties feasible. A major challenge in applying these methods to a true materials design is, however, the inclusion of temperature-driven effects on the desired properties. Therefore, a large range of computational tools has been developed in order to improve the capability and accuracy of first-principles methods in determining free energies. These combine electronic, vibrational and magnetic effects as well as structural defects in an integrated approach. Based on these simulation tools, one is now able to successfully predict mechanical and thermodynamic properties of metals with a hitherto not achievable accuracy.

Advancing density functional theory to finite temperatures: methods and applications in steel design.

PubMed

Hickel, T; Grabowski, B; Körmann, F; Neugebauer, J

2012-02-08

The performance of materials such as steels, their high strength and formability, is based on an impressive variety of competing mechanisms on the microscopic/atomic scale (e.g. dislocation gliding, solid solution hardening, mechanical twinning or structural phase transformations). Whereas many of the currently available concepts to describe these mechanisms are based on empirical and experimental data, it becomes more and more apparent that further improvement of materials needs to be based on a more fundamental level. Recent progress for methods based on density functional theory (DFT) now makes the exploration of chemical trends, the determination of parameters for phenomenological models and the identification of new routes for the optimization of steel properties feasible. A major challenge in applying these methods to a true materials design is, however, the inclusion of temperature-driven effects on the desired properties. Therefore, a large range of computational tools has been developed in order to improve the capability and accuracy of first-principles methods in determining free energies. These combine electronic, vibrational and magnetic effects as well as structural defects in an integrated approach. Based on these simulation tools, one is now able to successfully predict mechanical and thermodynamic properties of metals with a hitherto not achievable accuracy.

Effects of Post-Weld Heat Treatment on the Mechanical Properties of Similar- and Dissimilar-Alloy Friction Stir Welded Blanks

NASA Astrophysics Data System (ADS)

Zadpoor, Amir Abbas; Sinke, Jos

2011-01-01

Friction stir welding is a solid state joining process with relatively low welding temperatures. Nevertheless, the mechanical properties of friction stir welded blanks are degraded after welding. Indeed, both strength and ductility of the welds are decreased after welding. Often, the resulting friction stir welded blanks need to be formed to their final structural shape. Therefore, the formability of friction stir welded blanks is of primary importance in the manufacturing of structural parts. This paper studies how the mechanical properties and particularly formability of friction stir welded blanks can be improved by applying a post weld heat treatment. Two aluminum alloys from 2000 and 7000 series, namely 2024-T3 and 7075-T6, are selected for the study. The sheet thickness of both materials is 2,0 mm. The selected alloys are welded in three configurations: 2024-T3 and 2024-T3, 7075-T6 and 7075-T6, and 2024-T3 and 7075-T6. The resulting welds are naturally aged for a few months. Three sets of standard dog bone shape tensile test specimens are then machined from the welds. The first set of the specimens is tested without any heat treatment. The second set of the specimens is solution heat treated and quenched before testing. The third set of the specimens is solution heat treated, quenched, and naturally aged for a week before testing. The mechanical properties of the three different sets of specimens are compared with each other. It is shown that careful selection of post weld heat-treatment can greatly improve the formability of friction stir welded blanks.

Influence of hydrogen on formability and bendability of DP1180 steel for car body application

NASA Astrophysics Data System (ADS)

Gao, Q.; Han, F.; Wortberg, D.; Bleck, W.; Liewald, M.

2016-11-01

In order to reach future light weight targets, it is increasing necessary to use advanced high strength steels with tensile strength 980 MPa or higher in automotive body-inwhite structures. Due to the sensitivity to hydrogen embrittlement and the limited understanding of various aspects of hydrogen embrittlement on processing and function, the wide application of these steels is still limited. In the current work, the influence of hydrogen on the multiaxial forming behavior was investigated by determining the forming limit curve and bending limit curve of DP1180 steel. Hydrogen concentration in the material was modified by cathodic charging. Then Nakajima tests on hydrogen uncharged and pre-charged samples were carried out in order to adjust and study different strain states resulting in the forming limit curve. In the study of bending limit curve, the steel sheets were pre-strained by Marciniak test. Bending load on the uncharged and pre-charged samples was introduced by VDA238-100 bending tests. The experimental results indicated that the presence of hydrogen affected the formability and bendability of DP1180 steel. A clear difference in the influence of hydrogen at different strain states was observed. When formed in a biaxial strain state via the Nakajima test, the material showed the highest degradation in formability. Moreover, the samples with biaxial pre-loading showed more degradation in bendability comparing to those pre-strained in plane strain and uni-axial paths. Fractography by scanning electron microscope gave evidence of hydrogen-induced cleavage fracture on pre-charged Nakajima samples. Thus this investigation improves the understanding of influences of hydrogen on forming processes and provides important evidence for further studies on HE susceptibility of AHSS for the application on car body constructions.

Evolutions of Advanced Stamping CAE — Technology Adventures and Business Impact on Automotive Dies and Stamping

NASA Astrophysics Data System (ADS)

Wang, Chuantao (C. T.)

2005-08-01

In the past decade, sheet metal forming and die development has been transformed to a science-based and technology-driven engineering and manufacturing enterprise from a tryout-based craft. Stamping CAE, especially the sheet metal forming simulation, as one of the core components in digital die making and digital stamping, has played a key role in this historical transition. The stamping simulation technology and its industrial applications have greatly impacted automotive sheet metal product design, die developments, die construction and tryout, and production stamping. The stamping CAE community has successfully resolved the traditional formability problems such as splits and wrinkles. The evolution of the stamping CAE technology and business demands opens even greater opportunities and challenges to stamping CAE community in the areas of (1) continuously improving simulation accuracy, drastically reducing simulation time-in-system, and improving operationalability (friendliness), (2) resolving those historically difficult-to-resolve problems such as dimensional quality problems (springback and twist) and surface quality problems (distortion and skid/impact lines), (3) resolving total manufacturability problems in line die operations including blanking, draw/redraw, trim/piercing, and flanging, and (4) overcoming new problems in forming new sheet materials with new forming techniques. In this article, the author first provides an overview of the stamping CAE technology adventures and achievements, and industrial applications in the past decade. Then the author presents a summary of increasing manufacturability needs from the formability to total quality and total manufacturability of sheet metal stampings. Finally, the paper outlines the new needs and trends for continuous improvements and innovations to meet increasing challenges in line die formability and quality requirements in automotive stamping.

Forming an age hardenable aluminum alloy with intermediate annealing

NASA Astrophysics Data System (ADS)

Wang, Kaifeng; Carsley, John E.; Stoughton, Thomas B.; Li, Jingjing; Zhang, Lianhong; He, Baiyan

2013-12-01

A method to improve formability of aluminum sheet alloys by a two-stage stamping process with intermediate annealing was developed for a non-age hardenable Al-Mg alloy where the annealing heat treatment provided recovery of cold work from the initial stamping and recrystallization of the microstructure to enhance the forming limits of the material. This method was extended to an age hardenable, Al-Mg-Si alloy, which is complicated by the competing metallurgical effects during heat treatment including recovery (softening effect) vs. precipitation (hardening effect). An annealing heat treatment process condition was discovered wherein the stored strain energy from an initial plastic deformation can be sufficiently recovered to enhance formability in a second deformation; however, there is a deleterious effect on subsequent precipitation hardening. The improvement in formability was quantified with uniaxial tensile tests as well as with the forming limit diagram. Since strain-based forming limit curves (FLC) are sensitive to pre-strain history, both stress-based FLCs and polar-effective-plastic-strain (PEPS) FLCs, which are path-independent, were used to evaluate the forming limits after preform annealing. A technique was developed to calculate the stress-based FLC in which a residual-effective-plastic-strain (REPS) was determined by overlapping the hardening curve of the pre-strained and annealed material with that of the simply-annealed- material. After converting the strain-based FLCs using the constant REPS method, it was found that the stress-based FLCs and the PEPS FLCs of the post-annealed materials were quite similar and both tools are applicable for evaluating the forming limits of Al-Mg-Si alloys for a two-step stamping process with intermediate annealing.

Experimental and numerical investigation of dual phase steels formability during laser-assisted hole-flanging

NASA Astrophysics Data System (ADS)

Motaman, S. A. H.; Komerla, K.; Storms, T.; Prahl, U.; Brecher, C.; Bleck, W.

2018-05-01

Today, in the automotive industry dual phase (DP) steels are extensively used in the production of various structural parts due to their superior mechanical properties. Hole-flanging of such steels due to simultaneous bending and stretching of sheet metal, is complex and associated with some issues such as strain and strain rate localization, development of micro-cracks, inhomogeneous sheet thinning, etc. In this study an attempt is made to improve the formability of DP sheets, by localized Laser heating. The Laser beam was oscillated in circular pattern rapidly around the pre-hole, blanked prior to the flanging process. In order to investigate formability of DP steel (DP1000), several uniaxial tensile tests were conducted from quasi to intermediate strain rates at different temperatures in warm regime. Additionally, experimentally acquired temperature and strain rate-dependent flow curves were fed into thermomechanical finite element (FE) simulation of the hole-flanging process using the commercial FE software ABAQUS/Explicit. Several FE simulations were performed in order to evaluate the effect of blank's initial temperature and punch speed on deformation localization, stress evolution and temperature distribution in DP1000 sheets during warm hole-flanging process. The experimental and numerical analyses revealed that prescribing a distribution of initial temperature between 300 to 400 °C to the blank and setting a punch speed that accommodates strain rate range of 1 to 5 s-1 in the blank, provides the highest strain hardening capacity in the considered rate and temperature regimes for DP1000. This is in fact largely due to the dynamic strain aging (DSA) effect which occurs due to pinning of mobile dislocations by interstitial solute atoms, particularly at elevated temperatures.

Repair Options for Airframes

DTIC Science & Technology

2001-03-01

typical applications. This patch configuration can be best obtained with unidirectional tape . Woven material has greater formability and could also...1979. 15. Erdogan F and Arn K, "A Sandwich Plate With a Part-Through and a Debonding Crack," Engineering Fracture Mechanics, Vol. 4, June 1972. 16

Prevention of crack in stretch flanging process using hot stamping technique

NASA Astrophysics Data System (ADS)

Syafiq, Y. Mohd; Hamedon, Z.; Azila Aziz, Wan; Razlan Yusoff, Ahmad

2017-10-01

Demand for enhancing of passenger safety as well as weight reduction of automobiles has increased the use of high strength steel sheets. As a sheet metal is a lightweight having high strength is suitable for producing automotive parts such as white body panel. The stretch flanging of the high strength steel sheet is a problem due to high springback and easy to crack. This study uses three methods to stretch flange the sheets; using lubricants, shear-edge polishing and hot stamping. The effectiveness of these methods will be measured by comparing the flange length of each methods can achieved. For stretch flange with lubricant and polished sheared edge, the flange length failed to achieve the target 15 mm while hot stamping improved the formability of the sheet and preventing the occurrence of the springback and crack. Hot stamping not only improved formability of the sheet but also transformed the microstructure into martensite thus improve the hardness and the strength of the sheet after been quenched with the dies.

The impact of hydrogen on the formability of AHSS in Nakajima tests

NASA Astrophysics Data System (ADS)

Gao, Qi; Han, Fei; Wortberg, Daniel; Bleck, Wolfgang; Liewald, Mathias

2016-10-01

The application of Advanced High Strength Steels (AHSS) in the design of automotive body-in-white structures meets the requirement of light weight construction. The susceptibility to Hydrogen Embrittlement however, limits the wide application of steel grades over 1000 MPa. Up to now, various published studies focused on the hydrogen effects on mechanical properties; the impact of hydrogen on formability was not clarified. The present work aims to evaluate the influence of hydrogen on forming limit and fracture behavior in different strain states during the forming process. The hydrogen concentration in the material was modified by cathodic electro-charging. Nakajima tests in three strain conditions on uncharged and pre-charged samples were carried out. The localized necking was determined on the basis of the representative thinning rate in necking areas. The results revealed the shift of forming limits and critical strains to fracture owing to the presence of massive hydrogen. The fractography by Scanning Electron Microscope gave evidence of typical hydrogen-induced cleavage fracture on pre-charged samples.

Laser-assisted metal spinning for an efficient and flexible processing of challenging materials

NASA Astrophysics Data System (ADS)

Brummer, C.; Eck, S.; Marsoner, S.; Arntz, K.; Klocke, F.

2016-03-01

The demand for components made from high performance materials like titanium or nickel-based alloys as well as strain-hardening stainless steel is steadily increasing. However, conventional forming operations conducted on these materials are generally very laborious and time-consuming. This is where the limitations of metal spinning also become apparent. Using a laser to apply heat localized to the forming zone during metal spinning facilitates to enhance the formability of a material. In order to analyse the potential of the new manufacturing process, experimental investigations on laser-assisted shear forming and multi-pass metal spinning have been performed with austenitic stainless steel X5CrNi18-10, nickel-based alloy Inconel 718 and titanium grade 2. It could be demonstrated that the formability of these materials can be enhanced by laser-assistance. Besides the resulting enhancement of forming limits for metal spinning of challenging materials, the forming forces were reduced and the product quality was improved significantly.

Large strain cruciform biaxial testing for FLC detection

NASA Astrophysics Data System (ADS)

Güler, Baran; Efe, Mert

2017-10-01

Selection of proper test method, specimen design and analysis method are key issues for studying formability of sheet metals and detection of their forming limit curves (FLC). Materials with complex microstructures may need an additional micro-mechanical investigation and accurate modelling. Cruciform biaxial test stands as an alternative to standard tests as it achieves frictionless, in-plane, multi-axial stress states with a single sample geometry. In this study, we introduce a small-scale (less than 10 cm) cruciform sample allowing micro-mechanical investigation at stress states ranging from plane strain to equibiaxial. With successful specimen design and surface finish, large forming limit strains are obtained at the test region of the sample. The large forming limit strains obtained by experiments are compared to the values obtained from Marciniak-Kuczynski (M-K) local necking model and Cockroft-Latham damage model. This comparison shows that the experimental limiting strains are beyond the theoretical values, approaching to the fracture strain of the two test materials: Al-6061-T6 aluminum alloy and DC-04 high formability steel.

Crystal plasticity modelling of shear band deformation and its effect on the formability of Mg-3Al-1Zn sheets

NASA Astrophysics Data System (ADS)

Chen, Shuai-Feng; Song, Hong-Wu; Zhang, Shi-Hong

2017-09-01

Shear bands is a kind of typical microstructure in magnesium alloy which has drawn much attention during recent years. The formation of shear bands during the isothermal differential speed rolling of Mg-3Al-1Zn sheets is analysed by experimental methods. In addition, results of Erichsen and tensile tests indicate that the shear bands have an obvious effect on the anisotropic fracture behaviour and formability of magnesium alloy. A represent volume element (RVE) method combined with crystal plasticity model is established to investigate the effect of shear bands on the anisotropic fracture behaviours systematically by considering the grain size, texture, width, and tilted angle. The simulation results disclose the above factors can induce discontinuous strain and stress between the shear band regions (SBRs) and non-shear band regions (NSBRs), but the grain size and tilted angle have much bigger effect than that of texture and width, leading to the fracture at the interface SBR and NSBR.

First Principle and Experimental Study for Site Preferences of Formability Improved Alloying Elements in Mg Crystal

NASA Astrophysics Data System (ADS)

Zeng, Ying; Jiang, Bin; Shi, Ouling; Quan, Gaofen; Al-Ezzi, Salih; Pan, FuSheng

2018-07-01

Some alloying elements (Al, Er, Gd, Li, Mn, Sn, Y, Zn) were proved recently by calculations or experiments to improve the formability of Mg alloys, but ignoring their site preference in Mg crystals during the calculated process. A crystallographic model was built via first principle calculations to predict the site preferences of these elements. Regularities between doping elements and site preferences were summarized. Meanwhile, in the basis of the crystallographic model, a series of formulas were deduced combining the diffraction law. It predicted that a crystal plane with abnormal XRD peak intensity of the Mg-based solid solutions, compared to that of the pure Mg, prefers to possess solute atoms. Thus, three single-phase solid solution alloys were then prepared through an original In-situ Solution Treatment, and their XRD patterns were compared. Finally, the experiment further described the site preferences of these solute atoms in Mg crystal, verifying the calculation results.

Combinatorial Strategies for the Development of Bulk Metallic Glasses

NASA Astrophysics Data System (ADS)

Ding, Shiyan

The systematic identification of multi-component alloys out of the vast composition space is still a daunting task, especially in the development of bulk metallic glasses that are typically based on three or more elements. In order to address this challenge, combinatorial approaches have been proposed. However, previous attempts have not successfully coupled the synthesis of combinatorial libraries with high-throughput characterization methods. The goal of my dissertation is to develop efficient high-throughput characterization methods, optimized to identify glass formers systematically. Here, two innovative approaches have been invented. One is to measure the nucleation temperature in parallel for up-to 800 compositions. The composition with the lowest nucleation temperature has a reasonable agreement with the best-known glass forming composition. In addition, the thermoplastic formability of a metallic glass forming system is determined through blow molding a compositional library. Our results reveal that the composition with the largest thermoplastic deformation correlates well with the best-known formability composition. I have demonstrated both methods as powerful tools to develop new bulk metallic glasses.

The effect of oxyalkylation and application of polymer dispersions on the thermoformability and extensibility of paper.

PubMed

Kouko, Jarmo; Setälä, Harri; Tanaka, Atsushi; Khakalo, Alexey; Ropponen, Jarmo; Retulainen, Elias

2018-04-15

Wood fiber-based packaging materials, as renewable materials, have growing market potential due to their sustainability. A new breakthrough in cellulose-based packaging requires some improvement in the mechanical properties of paper. Bleached softwood kraft pulp was mechanically treated, in two stages, using high- and low-consistency refining, sequentially. Chemical treatment of pulp using the oxyalkylation method was applied to modify a portion of fiber material, especially the fiber surface, and its compatibility with polymer dispersions including one carbohydrate polymer. The results showed that the compatibility of the cellulosic fibers with some polymers could be improved with oxyalkylation. By adjusting mechanical and chemical treatments, and the thermoforming conditions, the formability of paper was improved, but simultaneously the strength and stiffness decreased. The results suggest that the formability of the paper is not a direct function of the extensibility of the applied polymer, but also depends on the fiber network structure and surface energy. Copyright © 2018 The Authors. Published by Elsevier Ltd.. All rights reserved.

First Principle and Experimental Study for Site Preferences of Formability Improved Alloying Elements in Mg Crystal

NASA Astrophysics Data System (ADS)

Zeng, Ying; Jiang, Bin; Shi, Ouling; Quan, Gaofen; Al-Ezzi, Salih; Pan, FuSheng

2018-03-01

Some alloying elements (Al, Er, Gd, Li, Mn, Sn, Y, Zn) were proved recently by calculations or experiments to improve the formability of Mg alloys, but ignoring their site preference in Mg crystals during the calculated process. A crystallographic model was built via first principle calculations to predict the site preferences of these elements. Regularities between doping elements and site preferences were summarized. Meanwhile, in the basis of the crystallographic model, a series of formulas were deduced combining the diffraction law. It predicted that a crystal plane with abnormal XRD peak intensity of the Mg-based solid solutions, compared to that of the pure Mg, prefers to possess solute atoms. Thus, three single-phase solid solution alloys were then prepared through an original In-situ Solution Treatment, and their XRD patterns were compared. Finally, the experiment further described the site preferences of these solute atoms in Mg crystal, verifying the calculation results.

Enhanced Densification of White Cast Iron Powders by Cyclic Phase Transformations under Stress.

DTIC Science & Technology

1981-08-01

Little or no significant enhancement in densification was reported in these cases where no applied stresses were used. Kohara [9) extended this work...enhancement of densification observed by Kohara , although limited, was attributed to the occurrence of transformation superplasticity. As will be shown... Kohara : Metall. Trans., 1976, vol. 7, p. 1239. 10. Y. Oshida, J. Jpn. Soc, Powder and Powder Metall., 1975, vol. 22, p. 147. 11. M. de Jong and G. W

Indirect Versus Direct Heating of Sheet Materials: Superplastic Forming and Diffusion Bonding Using Lasers

NASA Astrophysics Data System (ADS)

Jocelyn, Alan; Kar, Aravinda; Fanourakis, Alexander; Flower, Terence; Ackerman, Mike; Keevil, Allen; Way, Jerome

2010-06-01

Many from within manufacturing industry consider superplastic forming (SPF) to be ‘high tech’, but it is often criticized as too complicated, expensive, slow and, in general, an unstable process when compared to other methods of manipulating sheet materials. Perhaps, the fundamental cause of this negative perception of SPF, and also of diffusion bonding (DB), is the fact that the current process of SPF/DB relies on indirect sources of heating to produce the conditions necessary for the material to be formed. Thus, heat is usually derived from the electrically heated platens of hydraulic presses, to a lesser extent from within furnaces and, sometimes, from heaters imbedded in ceramic moulds. Recent evaluations of these isothermal methods suggest they are slow, thermally inefficient and inappropriate for the process. In contrast, direct heating of only the material to be formed by modern, electrically efficient, lasers could transform SPF/DB into the first choice of designers in aerospace, automotive, marine, medical, architecture and leisure industries. Furthermore, ‘variable temperature’ direct heating which, in theory, is possible with a laser beam(s) may provide a means to control material thickness distribution, a goal of enormous importance as fuel efficient, lightweight structures for transportation systems are universally sought. This paper compares, and contrasts, the two systems and suggests how a change to laser heating might be achieved.

Plastic Flow and Microstructure Evolution during Thermomechanical Processing of a PM Nickel-Base Superalloy

NASA Astrophysics Data System (ADS)

Semiatin, S. L.; McClary, K. E.; Rollett, A. D.; Roberts, C. G.; Payton, E. J.; Zhang, F.; Gabb, T. P.

2013-06-01

Plastic flow and microstructure evolution during sub- and supersolvus forging and subsequent supersolvus heat treatment of the powder-metallurgy superalloy LSHR (low-solvus, high-refractory) were investigated to develop an understanding of methods that can be used to obtain a moderately coarse gamma grain size under well-controlled conditions. To this end, isothermal, hot compression tests were conducted over broad ranges of temperature [(1144 K to 1450 K) 871 °C to 1177 °C] and constant true strain rate (0.0005 to 10 s-1). At low temperatures, deformation was generally characterized by flow softening and dynamic recrystallization that led to a decrease in grain size. At high subsolvus temperatures and low strain rates, steady-state flow or flow hardening was observed. These latter behaviors were ascribed to superplastic deformation and microstructure evolution characterized by a constant grain size or concomitant dynamic grain growth, respectively. During supersolvus heat treatment following subsolvus deformation, increases in grain size whose magnitude was a function of the prior deformation conditions were noted. A transition in flow behavior from superplastic to nonsuperplastic and the development during forging at a high subsolvus temperature of a wide (possibly bi- or multimodal) gamma-grain-size distribution having some large grains led to a substantially coarser grain size during supersolvus annealing in comparison to that produced under all other forging conditions.

Roll-to-Roll Nanoforming of Metals Using Laser-Induced Superplasticity.

PubMed

Goswami, Debkalpa; Munera, Juan C; Pal, Aniket; Sadri, Behnam; Scarpetti, Caio Lui P G; Martinez, Ramses V

2018-05-24

This Letter describes a low-cost, scalable nanomanufacturing process that enables the continuous forming of thin metallic layers with nanoscale accuracy using roll-to-roll, laser-induced superplasticity (R2RLIS). R2RLIS uses a laser shock to induce the ultrahigh-strain-rate deformation of metallic films at room temperature into low-cost polymeric nanomolds, independently of the original grain size of the metal. This simple and inexpensive nanoforming method does not require access to cleanrooms and associated facilities, and can be easily implemented on conventional CO 2 lasers, enabling laser systems commonly used for rapid prototyping or industrial cutting and engraving to fabricate uniform and three-dimensional crystalline metallic nanostructures over large areas. Tuning the laser power during the R2RLIS process enables the control of the aspect ratio and the mechanical and optical properties of the fabricated nanostructures. This roll-to-roll technique successfully fabricates mechanically strengthened gold plasmonic nanostructures with aspect ratios as high as 5 that exhibit high oxidation resistance and strong optical field enhancements. The CO 2 laser used in R2RLIS can also integrate the fabricated nanostructures on transparent flexible substrates with robust interfacial contact. The ability to fabricate ultrasmooth metallic nanostructures using roll-to-roll manufacturing enables the large scale production, at a relatively low-cost, of flexible plasmonic devices toward emerging applications.

The Specific Volumes and Viscosities of the Ni-Zr Liquid Alloys and their Correlation with the Glass Formability of the Alloys

NASA Technical Reports Server (NTRS)

Ohsaka, K.; Chung, S. K.; Rhim, W. K.

1997-01-01

The specific volumes and viscosities of the Ni-Zr liquid alloys as a function of temperature are determined by employing a digitizing technique and numeric analysis methods applied to the optical images of the electrostatically levitated liquid alloys.

Development of structural test articles from magnesium-lithium and beryllium

NASA Technical Reports Server (NTRS)

Alario, R.

1969-01-01

Study on the fabrication and testing of a magnesium-lithium box beam shows the formability and machinability characteristics of that alloy to be excellent. Results of forming tests for shrink and stretch flanges show values for both flange heights that may be used in future beryllium design.

TAZ-8A Alloy Increases The Thermal Endurance Of Steel

NASA Technical Reports Server (NTRS)

Waters, William J.

1990-01-01

TAZ-8A exhibits high strength at temperatures as high as 1,400 degrees F (760 degrees C) and resistance to oxidation; also exhibits excellent cyclic shock resistance between 600 and 2,000 degrees F (316 and 1,093 degrees C) and superplasticity at 1,800 degrees F (982 degrees C). Converts into fine powder and then flame-, plasma-, arc-, or wire-sprayed onto inexpensive steel substrate. Surface treatment with this alloy prolongs service life and reduces costs.

Processing and Properties of Airframe Materials.

DTIC Science & Technology

1987-06-01

size to develop a composite with 61% fine grains mixed with 39% coarse grains by volume. The stack was placed inside a stainless steel vacuum bag and...alloys, considerable interest exists for superplastic forming of the alloys. However, the first order priority is to consolidate a void- free and...1o- 0 1 5 " 20 25 Oelto K. bPa (sqrt(m)) Fig. 3.3-38 Secondary cracking vs AK, forged material, as-forged, heat treatment No. 2, including load shed

Silicon as anode for high-energy lithium ion batteries: From molten ingot to nanoparticles

NASA Astrophysics Data System (ADS)

Leblanc, Dominic; Hovington, Pierre; Kim, Chisu; Guerfi, Abdelbast; Bélanger, Daniel; Zaghib, Karim

2015-12-01

In this work, we demonstrate that a new mechanical attrition process can be used to prepare nanosilicon powder from metallurgical grade silicon lumps. Composite Li-ion anode made from this nanometer-size powder was found to have a high reversible capacity of 2400 mAh g-1 and an improved cycling stability compared to micrometer-sized powder. It is proposed that improved battery cycling performance is ascribed to the nanoscale silicon particles which supresses the volume expansion owing to its superplasticity.

Microstructure Evolution and Mechanical Behavior of Ultrafine Ti-6Al-4V During Low Temperature Superplastic Deformation (Postprint)

DTIC Science & Technology

2016-09-13

through the deformed β matrix . A total elongation of 1000% and strain-rate-sensitivity exponent m = 0.48 were obtained at 550 °C and 2 × 10−4 s−1...two orders of magnitude faster than the corresponding static behaviors due to enhanced diffusion through the deformed b matrix . A total elongation of...various metallic materials, including titanium alloys, is usually the result of concurrent grain- or interphase-boundary sliding, grain- matrix

Superplastic Behavior of Ti-6Al-4V-0.1B Alloy (Preprint)

DTIC Science & Technology

2011-10-01

Scott (UES, Inc.) for help with running the high temperature tension tests. The Ti-6Al-4V-0.1B sheets used in this study were fabricated in...collaboration with Scott Reed (Flowserve) and Oscar Yu (RTI) under EMTEC Project CT-86. 6 Approved for public release; distribution unlimited. References...Sun, M. Bennett, and J.M. Scott , “Production of Plates and Sheets from As-Cast Ti-6Al-4V via Boron Modification”, in: Ti-2007 Science and Technology

Low cost, formable, high T(sub c) superconducting wire

NASA Technical Reports Server (NTRS)

Smialek, James L. (Inventor)

1991-01-01

A ceramic superconductivity part such as a wire is produced through the partial oxidation of a specially formulated copper alloy in the core. The alloys contain low level quantities of rare earth and alkaline earth dopant elements. Upon oxidation at high temperature, superconducting oxide phases are formed as a thin film.

Quasicrystal-reinforced Mg alloys.

PubMed

Kyun Kim, Young; Tae Kim, Won; Hyang Kim, Do

2014-04-01

The formation of the icosahedral phase (I-phase) as a secondary solidification phase in Mg-Zn-Y and Mg-Zn-Al base systems provides useful advantages in designing high performance wrought magnesium alloys. The strengthening in two-phase composites (I-phase + α -Mg) can be explained by dispersion hardening due to the presence of I-phase particles and by the strong bonding property at the I-phase/matrix interface. The presence of an additional secondary solidification phase can further enhance formability and mechanical properties. In Mg-Zn-Y alloys, the co-presence of I and Ca 2 Mg 6 Zn 3 phases by addition of Ca can significantly enhance formability, while in Mg-Zn-Al alloys, the co-presence of the I-phase and Mg 2 Sn phase leads to the enhancement of mechanical properties. Dynamic and static recrystallization are significantly accelerated by addition of Ca in Mg-Zn-Y alloy, resulting in much smaller grain size and more random texture. The high strength of Mg-Zn-Al-Sn alloys is attributed to the presence of finely distributed Mg 2 Sn and I-phase particles embedded in the α -Mg matrix.

Quasicrystal-reinforced Mg alloys

PubMed Central

Kyun Kim, Young; Tae Kim, Won; Hyang Kim, Do

2014-01-01

The formation of the icosahedral phase (I-phase) as a secondary solidification phase in Mg–Zn–Y and Mg–Zn–Al base systems provides useful advantages in designing high performance wrought magnesium alloys. The strengthening in two-phase composites (I-phase + α-Mg) can be explained by dispersion hardening due to the presence of I-phase particles and by the strong bonding property at the I-phase/matrix interface. The presence of an additional secondary solidification phase can further enhance formability and mechanical properties. In Mg–Zn–Y alloys, the co-presence of I and Ca2Mg6Zn3 phases by addition of Ca can significantly enhance formability, while in Mg–Zn–Al alloys, the co-presence of the I-phase and Mg2Sn phase leads to the enhancement of mechanical properties. Dynamic and static recrystallization are significantly accelerated by addition of Ca in Mg–Zn–Y alloy, resulting in much smaller grain size and more random texture. The high strength of Mg–Zn–Al–Sn alloys is attributed to the presence of finely distributed Mg2Sn and I-phase particles embedded in the α-Mg matrix. PMID:27877660

EBSD characterization of twinning in cold-rolled CP-Ti

DOE Office of Scientific and Technical Information (OSTI.GOV)

Li, X., E-mail: csulixu@hotmail.com; Duan, Y.L., E-mail: 876270744@qq.com; Xu, G.F., E-mail: csuxgf66@csu.edu.cn

2013-10-15

This work presents the use of a mechanical testing system and the electron backscatter diffraction technique to study the mechanical properties and twinning systems of cold-rolled commercial purity titanium, respectively. The dependence of twinning on the matrix orientation is analyzed by the distribution map of Schmid factor. The results showed that the commercial purity titanium experienced strong strain hardening and had excellent formability during rolling. Both the (112{sup ¯}2)<112{sup ¯}3{sup ¯}> compressive twins and (101{sup ¯}2)<101{sup ¯}1{sup ¯}> tensile twins were dependent on the matrix orientation. The Schmid factor of a grain influenced the activation of a particular twinning system.more » The specific rolling deformation of commercial purity titanium controlled the number and species of twinning systems and further changed the mechanical properties. - Highlights: • CP-Ti experienced strain hardening and had excellent formability. • Twins were dependent on the matrix orientation. • Schmid factor of a grain influenced the activation of a twinning system. • Rolling deformation controlled twinning systems and mechanical properties.« less

Nanometric Scale Investigation of Phase Transformations in Advanced Steels for Automotive Application

NASA Astrophysics Data System (ADS)

Drillet, Josée; Valle, Nathalie; Iung, Thierry

2012-12-01

The current trend toward producing lighter vehicles in the automotive industry is driven by the need to conform to the new exhaust emission control regulations. This objective presents a challenge to steel manufacturers. The difficulty lies in designing new alloys with an optimum strength/formability/cost balance for the various components. Here, the key to success lies in controlling the steel microstructure and especially the phase transformations at the smallest possible scale. Among the different alloying elements, light elements such as carbon and boron are of prime importance due to their major effects on the kinetics of phase transformations. Characterization tools combining high spatial and analytical resolution such as secondary ion mass spectrometry (SIMS) and field emission gun-transmission electron microscopy (TEM) were used. In this article, the examples presented are as follows. (1) Boron segregation and precipitation effects to control hardenability in martensitic steels. (2) Local carbon distribution in advanced high-strength steels, with a specific emphasis on martensite tempering. Links have been established between the boron and carbon distribution and the formability.

Determination of Proper Austenitization Temperatures for Hot Stamping of AISI 4140 Steel

NASA Astrophysics Data System (ADS)

Samadian, Pedram; Parsa, Mohammad Habibi; Shakeri, Amid

2014-04-01

High strength steels are desirable materials for use in automobile bodies in order to reduce vehicle weight and increase the safety of car passengers, but steel grades with high strength commonly show poor formability. Recently, steels with controlled microstructures and compositions are used to gain adequate strength after hot stamping while maintaining good formability during processing. In this study, microstructure evolutions and changes in mechanical properties of AISI 4140 steel sheets resulting from the hot stamping process at different austenitization temperatures were investigated. To determine the proper austenitization temperatures, the results were compared with those of the cold-worked and cold-worked plus quench-tempered specimens. Comparisons showed that the austenitization temperatures of 1000 and 1100 °C are proper for hot stamping of 3-mm-thick AISI 4140 steel sheets due to the resultant martensitic microstructure which led to the yield and ultimate tensile strength of 1.3 and 2.1 GPa, respectively. Such conditions resulted in more favorable simultaneous strength and elongation than those of hot-stamped conventional boron steels.

Effect of Temperature and Dynamic Loading on the Mechanical Properties of Copper-Alloyed High-Strength Interstitial-Free Steel

NASA Astrophysics Data System (ADS)

Rana, R.; Singh, S. B.; Bleck, W.; Mohanty, O. N.

2009-04-01

Crash resistance and formability relevant mechanical properties of a copper-alloyed interstitial-free (IF) steel processed under various conditions of batch annealing (BA), continuous annealing (CA), and postcontinuous annealing aging have been studied in a wide range of strain rate (3.33 × 10-4 to 200 s-1) and temperature (-100 °C to +20 °C). These properties have been compared with similarly processed traditional mild and high-strength IF steels. Assessment of various parameters such as strength, elongation, strain rate sensitivity of stress, strain-hardening capacity, temperature sensitivity of stress, activation volume, and specific energy absorption of all these steels implies that copper-alloyed IF steel is soft and formable in CA condition. It can be made stronger and more crash resistant than the conventional mild- or high-strength IF steels when aged to peak strength after CA. Room-temperature strain rate sensitivity of stress of the investigated steels exhibits a two-stage behavior. Copper in solution in ferrite causes solid solution softening at low temperatures (≤20 °C) and at high strain rates (200 s-1).

Experimental and Numerical Studies on the Formability of Materials in Hot Stamping and Cold Die Quenching Processes

NASA Astrophysics Data System (ADS)

Li, N.; Mohamed, M. S.; Cai, J.; Lin, J.; Balint, D.; Dean, T. A.

2011-05-01

Formability of steel and aluminium alloys in hot stamping and cold die quenching processes is studied in this research. Viscoplastic-damage constitutive equations are developed and determined from experimental data for the prediction of viscoplastic flow and ductility of the materials. The determined unified constitutive equations are then implemented into the commercial Finite Element code Abaqus/Explicit via a user defined subroutine, VUMAT. An FE process simulation model and numerical procedures are established for the modeling of hot stamping processes for a spherical part with a central hole. Different failure modes (failure takes place either near the central hole or in the mid span of the part) are obtained. To validate the simulation results, a test programme is developed, a test die set has been designed and manufactured, and tests have been carried out for the materials with different forming rates. It has been found that very close agreements between experimental and numerical process simulation results are obtained for the ranges of temperatures and forming rates carried out.

Influence of temperature and friction on the 22MnB5 formability under hot stamping conditions

NASA Astrophysics Data System (ADS)

Venturato, G.; Ghiotti, A.; Bruschi, S.

2018-05-01

The need to increase the safety and decrease the weight of the car body-in-white has determined the success of the direct hot stamping process as a primary technology for the automotive sector. Thanks to this process, parts with high strength-to-weight ratio can be obtained along with high stiffness and increase of the crashworthiness properties. Moreover, the thinner metal sheets used to manufacture the pieces lead to a decrease of the total weight of the car body-in-white, with a consequent reduction of the CO2 emissions. The direct hot stamping process is becoming the key to obtain pieces with high mechanical properties, thanks to the quenching stage that allows the manufacture of complex shapes characterized by a fully martensitic structure, thanks to the forming stage at elevated temperature and subsequent hardening inside the cooled dies. The aim of this paper is the investigation of the influence that the forming temperature may have on the formability of 22MnB5 steel sheets, commonly used in the hot stamping process of automotive components. Nakajima tests were carried out at different temperatures and the Forming Limit Diagrams (FLDs) at rupture were obtained and analysed. The temperature influenced both the major and the minor strain at which the sheet failed, indicating that not only the formability increased at increasing temperature, but there was also a modification of the strain path, which means a modification of the strain states through which the part passes during the deformation process. Moreover, the influence of friction is studied using a model developed in the LS-Dyna FEM environment. The obtained data are of great importance for an accurate calibration of Finite Element (FE) models of the hot stamping of real components in order to get optimal process parameters to obtain defects-free pieces.

Strain Amount Dependent Grain Size and Orientation Developments during Hot Compression of a Polycrystalline Nickel Based Superalloy

PubMed Central

He, Guoai; Tan, Liming; Liu, Feng; Huang, Lan; Huang, Zaiwang; Jiang, Liang

2017-01-01

Controlling grain size in polycrystalline nickel base superalloy is vital for obtaining required mechanical properties. Typically, a uniform and fine grain size is required throughout forging process to realize the superplastic deformation. Strain amount occupied a dominant position in manipulating the dynamic recrystallization (DRX) process and regulating the grain size of the alloy during hot forging. In this article, the high-throughput double cone specimen was introduced to yield wide-range strain in a single sample. Continuous variations of effective strain ranging from 0.23 to 1.65 across the whole sample were achieved after reaching a height reduction of 70%. Grain size is measured to be decreased from the edge to the center of specimen with increase of effective strain. Small misorientation tended to generate near the grain boundaries, which was manifested as piled-up dislocation in micromechanics. After the dislocation density reached a critical value, DRX progress would be initiated at higher deformation region, leading to the refinement of grain size. During this process, the transformations from low angle grain boundaries (LAGBs) to high angle grain boundaries (HAGBs) and from subgrains to DRX grains are found to occur. After the accomplishment of DRX progress, the neonatal grains are presented as having similar orientation inside the grain boundary. PMID:28772514

Controlling microstructure and texture in magnesium alloy sheet by shear-based deformation processing

NASA Astrophysics Data System (ADS)

Sagapuram, Dinakar

Application of lightweight Mg sheet is limited by its low workability, both in production of sheet (typically by multistep hot and cold-rolling) and forming of sheet into components. Large strain extrusion machining (LSEM), a constrained chip formation process, is used to create Mg alloy AZ31B sheet in a single deformation step. The deformation in LSEM is shown to be intense simple shear that is confined to a narrow zone, which results in significant deformation-induced heating up to ~ 200°C and reduces the need for pre-heating to realize continuous sheet forms. This study focuses on the texture and microstructure development in the sheet processed by LSEM. Interestingly, deep, highly twinned steady-state layer develops in the workpiece subsurface due to the compressive field ahead of the shear zone. The shear deformation, in conjunction with this pre-deformed twinned layer, results in tilted-basal textures in the sheet with basal planes tilted well away from the surface. These textures are significantly different from those in rolled sheet, where basal planes are nearly parallel to the surface. By controlling the strain path, the basal plane inclination from the surface could be varied in the range of 32-53°. B-fiber (basal plane parallel to LSEM shear plane), associated with basal slip, is the major texture component in the sheet. An additional minor C2-fiber component appears above 250°C due to the thermal activation of pyramidal slip. Together with these textures, microstructure ranges from severely cold-worked to (dynamically) recrystallized type, with the corresponding grain sizes varying from ultrafine- (~ 200 nm) to fine- (2 mum) grained. Small-scale limiting dome height (LDH) confirmed enhanced formability (~ 50% increase in LDH) of LSEM sheet over the conventional rolled sheet. Premature, twinning-driven shear fractures are observed in the rolled sheet with the basal texture. In contrast, LSEM sheet with a tilted-basal texture favorably oriented for basal slip exhibits ductile tensile-type fracture. A two-fold increase in ductility is also observed for the LSEM sheet under uniaxial tensile testing without significant changes in the strength. Among texture and microstructure (grain size), texture is shown to be more critical for Mg sheet formability. However, in conjunction with a favorable texture, fine recrystallized microstructure provides for additional enhancement of strain-hardening capacity and formability. In-situ imaging of material flow during uniaxial tensile testing revealed new, interesting flow localization phenomena and fracture behavior. It is shown that the deformation behavior of Mg sheet is highly texture dependent, and also radically different from that of conventional ductile metals both in terms of necking and fracture. The implications of these observations for the LDH test results and formability of Mg sheet, in general, are briefly discussed.

Aircraft gas turbine materials and processes.

PubMed

Kear, B H; Thompson, E R

1980-05-23

Materials and processing innovations that have been incorporated into the manufacture of critical components for high-performance aircraft gas turbine engines are described. The materials of interest are the nickel- and cobalt-base superalloys for turbine and burner sections of the engine, and titanium alloys and composites for compressor and fan sections of the engine. Advanced processing methods considered include directional solidification, hot isostatic pressing, superplastic foring, directional recrystallization, and diffusion brazing. Future trends in gas turbine technology are discussed in terms of materials availability, substitution, and further advances in air-cooled hardware.

Method of forming low cost, formable High T(subc) superconducting wire

NASA Technical Reports Server (NTRS)

Smialek, James L. (Inventor)

1989-01-01

A ceramic superconductivity part, such as a wire, is produced through the partial oxidation of a specially formulated copper alloy in a core. The alloys contains low level of quantities of rare earth and alkaline earth dopant elements. Upon oxidation at high temperatures, and superconducting oxide phases are formed as a thin film.

Using Interactive Sketch Interpretation to Design Solid Objects

DTIC Science & Technology

1993-04-04

chair ........ .............................. 20 2.2.2 An exercise in geometry ................................. 22 3 Generating topologies from line...design on a solid modeler fall into four broad categories: direct generation, conistructive solid geometry (CSG), profile manipulation and de- formable...Constructive Solid Geometry to find the intersection of three correctly oriented rectangular slabs [3] (it is also possible to use four CSG "cuts" to

Fracture Toughness to Understand Stretch-Flangeability and Edge Cracking Resistance in AHSS

NASA Astrophysics Data System (ADS)

Casellas, Daniel; Lara, Antoni; Frómeta, David; Gutiérrez, David; Molas, Sílvia; Pérez, Lluís; Rehrl, Johannes; Suppan, Clemens

2017-01-01

The edge fracture is considered as a high risk for automotive parts, especially for parts made of advanced high strength steels (AHSS). The limited ductility of AHSS makes them more sensitive to the edge damage. The traditional approaches, such as those based on ductility measurements or forming limit diagrams, are unable to predict this type of fractures. Thus, stretch-flangeability has become an important formability parameter in addition to tensile and formability properties. The damage induced in sheared edges in AHSS parts affects stretch-flangeability, because the generated microcracks propagate from the edge. Accordingly, a fracture mechanics approach may be followed to characterize the crack propagation resistance. With this aim, this work addresses the applicability of fracture toughness as a tool to understand crack-related problems, as stretch-flangeability and edge cracking, in different AHSS grades. Fracture toughness was determined by following the essential work of fracture methodology and stretch-flangeability was characterized by means of hole expansions tests. Results show a good correlation between stretch-flangeability and fracture toughness. It allows postulating fracture toughness, measured by the essential work of fracture methodology, as a key material property to rationalize crack propagation phenomena in AHSS.

Multi objective Taguchi optimization approach for resistance spot welding of cold rolled TWIP steel sheets

NASA Astrophysics Data System (ADS)

Tutar, Mumin; Aydin, Hakan; Bayram, Ali

2017-08-01

Formability and energy absorption capability of a steel sheet are highly desirable properties in manufacturing components for automotive applications. TWinning Induced Plastisity (TWIP) steels are, new generation high Mn alloyed steels, attractive for the automotive industry due to its outstanding elongation (%40-45) and tensile strength (~1000MPa). So, TWIP steels provide excellent formability and energy absorption capability. Another required property from the steel sheets is suitability for manufacturing methods such as welding. The use of the steel sheets in the automotive applications inevitably involves welding. Considering that there are 3000-5000 welded spots on a vehicle, it can be interpreted that one of the most important manufacturing method is Resistance Spot Welding (RSW) for the automotive industry. In this study; firstly, TWIP steel sheet were cold rolled to 15% reduction in thickness. Then, the cold rolled TWIP steel sheets were welded with RSW method. The welding parameters (welding current, welding time and electrode force) were optimized for maximizing the peak tensile shear load and minimizing the indentation of the joints using a Taguchi L9 orthogonal array. The effect of welding parameters was also evaluated by examining the signal-to-noise ratio and analysis of variance (ANOVA) results.

Computational studies of the glass-forming ability of model bulk metallic glasses

NASA Astrophysics Data System (ADS)

Zhang, Kai; Wang, Minglei; Papanikolaou, Stefanos; Liu, Yanhui; Schroers, Jan; Shattuck, Mark D.; O'Hern, Corey S.

2013-09-01

Bulk metallic glasses (BMGs) are produced by rapidly thermally quenching supercooled liquid metal alloys below the glass transition temperature at rates much faster than the critical cooling rate Rc below which crystallization occurs. The glass-forming ability of BMGs increases with decreasing Rc, and thus good glass-formers possess small values of Rc. We perform molecular dynamics simulations of binary Lennard-Jones (LJ) mixtures to quantify how key parameters, such as the stoichiometry, particle size difference, attraction strength, and heat of mixing, influence the glass-formability of model BMGs. For binary LJ mixtures, we find that the best glass-forming mixtures possess atomic size ratios (small to large) less than 0.92 and stoichiometries near 50:50 by number. In addition, weaker attractive interactions between the smaller atoms facilitate glass formation, whereas negative heats of mixing (in the experimentally relevant regime) do not change Rc significantly. These results are tempered by the fact that the slowest cooling rates achieved in our simulations correspond to ˜1011 K/s, which is several orders of magnitude higher than Rc for typical BMGs. Despite this, our studies represent a first step in the development of computational methods for quantitatively predicting glass-formability.

Characterization and Formability of Titanium/Aluminum Laminate Composites Fabricated by Hot Pressing

NASA Astrophysics Data System (ADS)

Qin, Liang; Wang, Hui; Cui, Shengqiang; Wu, Qian; Fan, Minyu; Yang, Zonghui; Tao, Jie

2017-07-01

The Ti/Al laminate composites were prepared by hot pressing to investigate the forming performance due to the corresponding potential applications in both the aerospace and auto industry. The bonding interface morphology and element distributions were characterized by SEM and EDS. The phase constituent was detected by XRD. It was observed that these composites presented good bonding interfaces between Ti and Al layers, and no low-sized voids and intermetallic compounds formed at the interface. In addition, the formability of these laminate composites was studied by the uniaxial tension tests, the limit drawing ratio (LDR) and the forming limit curve (FLC) experiments, respectively. The results indicated that the flow stress increased along with the strain rate increment. A constitutive equation was developed for deformation behavioral description of these laminate composites. The LDR value was 1.8, and the most susceptible region to present cracks was located at the punch profile radius. The forming limit curve of the laminate composites was located between the curves of titanium and aluminum and intersected with the major strain line at approximately 0.31. The macroscopic cracks of the FLC sample demonstrated a saw-toothed crack feature.

Performance evaluation of bipolar and tripolar excitations during nozzle-jetting-based alginate microsphere fabrication

NASA Astrophysics Data System (ADS)

Herran, C. Leigh; Huang, Yong; Chai, Wenxuan

2012-08-01

Microspheres, small spherical (polymeric) particles with or without second phase materials embedded or encapsulated, are important for many biomedical applications such as drug delivery and organ printing. Scale-up fabrication with the ability to precisely control the microsphere size and morphology has always been of great manufacturing interest. The objective of this work is to experimentally study the performance differences of bipolar and tripolar excitation waveforms in using drop-on-demand (DOD)-based single nozzle jetting for alginate microsphere fabrication. The fabrication performance has been evaluated based on the formability of alginate microspheres as a function of materials properties (sodium alginate and calcium chloride concentrations) and operating conditions. The operating conditions for each excitation include voltage rise/fall times, dwell times and excitation voltage amplitudes. Overall, the bipolar excitation is more robust in making spherical, monodispersed alginate microspheres as good microspheres for its wide working range of material properties and operating conditions, especially during the fabrication of highly viscous materials such as the 2% sodium alginate solution. For both bipolar and tripolar excitations, the sodium alginate concentration and the voltage dwell times should be carefully selected to achieve good microsphere formability.

Forming of AHSS using Servo-Presses

NASA Astrophysics Data System (ADS)

Groseclose, Adam Richard

Stamping of Advanced High Strength Steel (AHSS) alloys poses several challenges due to the material's higher strength and low formability compared to conventional steels and other problems such as (a) inconsistency of incoming material properties, (b) ductile fracture during forming, (c) higher contact pressure and temperature rise during forming, (d) higher die wear leading to reduced tool life, (e) higher forming load/press capacity, and (f) large springback leading to dimensional inaccuracy in the formed part. [Palaniswamy et. al., 2007]. The use of AHSS has been increasing steadily in automotive stamping. New AHSS alloys (TRIP, TWIP) may replace some of the Hot Stamping applications. Stamping of AHSS alloys, especially higher strength materials, 780 MPa and higher, present new challenges in obtaining good part definition (corner and fillet radii), formability (fracture and resulting scrap) and in reducing springback. Servo-drive presses, having the capability to have infinitely variable and adjustable ram speed and dwell at BDC, offer a potential improvement in quality, part definition, and springback reduction especially when the infinitely adjustable slide motion is used in combination with a CNC hydraulic cushion. Thus, it is desirable to establish a scientific/engineering basis for improving the stamping conditions in forming AHSS using a servo-drive press.

Effect of Material Thermo-viscoplastic Modeling on the Prediction of Forming Limit Curves of Aluminum Alloy 5086

NASA Astrophysics Data System (ADS)

Chu, Xingrong; Leotoing, Lionel; Guines, Dominique; Ragneau, Eric

2015-09-01

A solution to improve the formability of aluminum alloy sheets can consist in investigating warm forming processes. The optimization of forming process parameters needs a precise evaluation of material properties and sheet metal formability for actual operating environment. Based on the analytical M-K theory, a finite element (FE) M-K model was proposed to predict forming limit curves (FLCs) at different temperatures and strain rates. The influences of initial imperfection value ( f 0) and material thermos-viscoplastic model on the FLCs are discussed in this work. The flow stresses of AA5086 were characterized by uniaxial tensile tests at different temperatures (20, 150, and 200 °C) and equivalent strain rates (0.0125, 0.125, and 1.25 s-1). Three types of hardening models (power law model, saturation model, and mixed model) were proposed and adapted to correlate the experimental flow stresses. The three hardening models were implemented into the FE M-K model in order to predict FLCs for different forming conditions. The predicted limit strains are very sensitive to the thermo-viscoplastic modeling of AA5086 and to the calibration of the initial geometrical imperfection which controls the onset of necking.

Effect of Anisotropic Yield Function Evolution on Estimation of Forming Limit Diagram

NASA Astrophysics Data System (ADS)

Bandyopadhyay, K.; Basak, S.; Choi, H. J.; Panda, S. K.; Lee, M. G.

2017-09-01

In case of theoretical prediction of the FLD, the variations in yield stress and R-values along different material directions, were long been implemented to enhance the accuracy. Although influences of different yield models and hardening laws on formability were well addressed, anisotropic evolution of yield loci under monotonic loading with different deformation modes is yet to be explored. In the present study, Marciniak-Kuckzinsky (M-K) model was modified to incorporate the change in the shape of the initial yield function with evolution due to anisotropic hardening. Swift’s hardening law along with two different anisotropic yield criteria, namely Hill48 and Yld2000-2d were implemented in the model. The Hill48 yield model was applied with non-associated flow rule to comprehend the effect of variations in both yield stress and R-values. The numerically estimated FLDs were validated after comparing with FLD evaluated through experiments. A low carbon steel was selected, and hemispherical punch stretching test was performed for FLD evaluation. Additionally, the numerically estimated FLDs were incorporated in FE simulations to predict limiting dome heights for validation purpose. Other formability performances like strain distributions over the deformed cup surface were validated with experimental results.

Structural efficiency studies of corrugated compression panels with curved caps and beaded webs

NASA Technical Reports Server (NTRS)

Davis, R. C.; Mills, C. T.; Prabhakaran, R.; Jackson, L. R.

1984-01-01

Curved cross-sectional elements are employed in structural concepts for minimum-mass compression panels. Corrugated panel concepts with curved caps and beaded webs are optimized by using a nonlinear mathematical programming procedure and a rigorous buckling analysis. These panel geometries are shown to have superior structural efficiencies compared with known concepts published in the literature. Fabrication of these efficient corrugation concepts became possible by advances made in the art of superplastically forming of metals. Results of the mass optimization studies of the concepts are presented as structural efficiency charts for axial compression.

Deformation of Extruded Titanium Alloys Under Superplastic Conditions

DTIC Science & Technology

1988-07-01

176mm wide with a flange wall 37mm high x 27mm wide and a central web 122mm wide x 18mm thick. Round-bar test pieces aligned parallel to the principal...directions L, T and ST were extrac- ted from the flange and web as shown in Fig 1; gauge length dimensions were 15mm x 5.5mm diameter for the FST test...ares. in the gauge length. Flange Web X 9 NTIS GFA&I v FL Distribut I oc / A es ’- n:ia or Fig I Position of test pieces in extruded section iste i

Technology development status at McDonnell Douglas

NASA Technical Reports Server (NTRS)

Rowe, W. T.

1981-01-01

The significant technology items of the Concorde and the conceptual MCD baseline advanced supersonic transport are compared. The four major improvements are in the areas of range performance, structures (materials), aerodynamics, and in community noise. Presentation charts show aerodynamic efficiency; the reoptimized wing; low scale lift/drag ratio; control systems; structural modeling and analysis; weight and cost comparisons for superplasticity diffusion bonded titanium sandwich structures and for aluminum brazed titanium honeycomb structures; operating cost reduction; suppressor nozzles; noise reduction and range; the bicone inlet; a market summary; environmental issues; high priority items; the titanium wing and fuselage test components; and technology validation.

Effects of an AST program on US titanium story

NASA Technical Reports Server (NTRS)

Fitzsimmons, R. D.

1980-01-01

The singular importance of titanium as the primary structural material for an efficient advanced supersonic transport (AST) is outlined. The advantages of titanium over other metals are shown to apply to future subsonic aircraft as well as for supersonic designs. The cost problem of titanium is addressed and shown to be markedly reduced by the emerging technologies of superplastic forming/diffusion bonding sandwich, hot isostatic pressing of titanium powders, and isothermal forgings if demonstration programs should validate preliminary findings. The impact of a U.S. AST program on the United States titanium supply and demand picture is postulated.

Aircraft energy efficiency laminar flow control wing design study

NASA Technical Reports Server (NTRS)

Bonner, T. F., Jr.; Pride, J. D., Jr.; Fernald, W. W.

1977-01-01

An engineering design study was performed in which laminar flow control (LFC) was integrated into the wing of a commercial passenger transport aircraft. A baseline aircraft configuration was selected and the wing geometry was defined. The LFC system, with suction slots, ducting, and suction pumps was integrated with the wing structure. The use of standard aluminum technology and advanced superplastic formed diffusion bonded titanium technology was evaluated. The results of the design study show that the LFC system can be integrated with the wing structure to provide a structurally and aerodynamically efficient wing for a commercial transport aircraft.

Effect of geometrical parameters on pressure distributions of impulse manufacturing technologies

NASA Astrophysics Data System (ADS)

Brune, Ryan Carl

Impulse manufacturing techniques constitute a growing field of methods that utilize high-intensity pressure events to conduct useful mechanical operations. As interest in applying this technology continues to grow, greater understanding must be achieved with respect to output pressure events in both magnitude and distribution. In order to address this need, a novel pressure measurement has been developed called the Profile Indentation Pressure Evaluation (PIPE) method that systematically analyzes indentation patterns created with impulse events. Correlation with quasi-static test data and use of software-assisted analysis techniques allows for colorized pressure maps to be generated for both electromagnetic and vaporizing foil actuator (VFA) impulse forming events. Development of this technique aided introduction of a design method for electromagnetic path actuator systems, where key geometrical variables are considered using a newly developed analysis method, which is called the Path Actuator Proximal Array (PAPA) pressure model. This model considers key current distribution and proximity effects and interprets generated pressure by considering the adjacent conductor surfaces as proximal arrays of individual conductors. According to PIPE output pressure analysis, the PAPA model provides a reliable prediction of generated pressure for path actuator systems as local geometry is changed. Associated mechanical calculations allow for pressure requirements to be calculated for shearing, flanging, and hemming operations, providing a design process for such cases. Additionally, geometry effect is investigated through a formability enhancement study using VFA metalworking techniques. A conical die assembly is utilized with both VFA high velocity and traditional quasi-static test methods on varied Hasek-type sample geometries to elicit strain states consistent with different locations on a forming limit diagram. Digital image correlation techniques are utilized to measure major and minor strains for each sample type to compare limit strain results. Overall testing indicated decreased formability at high velocity for 304 DDQ stainless steel and increased formability at high velocity for 3003-H14 aluminum. Microstructural and fractographic analysis helped dissect and analyze the observed differences in these cases. Overall, these studies comprehensively explore the effects of geometrical parameters on magnitude and distribution of impulse manufacturing generated pressure, establishing key guidelines and models for continued development and implementation in commercial applications.

Manufacture of a four-sheet complex component from different titanium alloys by superplastic forming

NASA Astrophysics Data System (ADS)

Allazadeh, M. R.; Zuelli, N.

2017-10-01

A superplastic forming (SPF) technology process was deployed to form a complex component with eight-pocket from a four-sheet sandwich panel sheetstock. Six sheetstock packs were composed of two core sheets made of Ti-6Al-4V or Ti-5Al-4Cr-4Mo-2Sn-2Zr titanium alloy and two skin sheets made of Ti-6Al-4V or Ti-6Al-2Sn-4Zr-2Mo titanium alloy in three different combinations. The sheets were welded with two subsequent welding patterns over the core and skin sheets to meet the required component's details. The applied welding methods were intermittent and continuous resistance seam welding for bonding the core sheets to each other and the skin sheets over the core panel, respectively. The final component configuration was predicted based on the die drawings and finite element method (FEM) simulations for the sandwich panels. An SPF system set-up with two inlet gas pipe feeding facilitated the trials to deliver two pressure-time load cycles acting simultaneously which were extracted from FEM analysis for specific forming temperature and strain rate. The SPF pressure-time cycles were optimized via GOM scanning and visually inspecting some sections of the packs in order to assess the levels of core panel formation during the inflation process of the sheetstock. Two sets of GOM scan results were compared via GOM software to inspect the surface and internal features of the inflated multisheet packs. The results highlighted the capability of the tested SPF process to form complex components from a flat multisheet pack made of different titanium alloys.

JPRS Report, Science & Technology, Japan, High Temperature Materials

DTIC Science & Technology

1990-11-09

3 This restriction is heavy. The inconvenience that the material powder of the imido thermal composition method, for example, which shows the best...procedures, system composition , features of formability, and forming characteristic of forming samples using alumina material will be made. 2...Osmotic V Process Forming System 2.1 System Composition of Process A system block diagram of the process is shown in Figure 1. The V process forming system

Effect of TMP variables upon structure and properties in ODS alloy HDA 8077 sheet. [ThermoMechanical Processing of Oxide Dispersion Strengthened nickel alloy

NASA Technical Reports Server (NTRS)

Rothman, M. F.; Tawancy, H. M.

1980-01-01

The effects of oxide content level and variations in thermomechanical processing upon the final structure and properties of HDA 8077 sheet have been systematically examined. It was found that creep strength and formability are substantially influenced by both oxide content and TMP schedule. Variations in creep properties obtained appear to correlate with observed microstructures.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Huang, Cindy Xiaohui; Lim, Chao Voon; Castagne, Sylvie

Titanium and its alloys have a wide range of applications in various industries such as aerospace, medical, automotive and even commercial products. However, formability of titanium alloys has always been an issue. This study presents the results of an investigation on the workability and response of Ti-6Al-4V deformed at different strain rates and lower elevated temperatures with different initial microstructures. Compression tests of cylindrical specimens were performed at various temperatures (300 deg. C, 400 deg. C, 450 deg. C, 500 deg. C) and at different strain rates (0.001 s{sup -1}, 0.02 s{sup -1} and 0.1 s{sup -1}). The effects ofmore » strain rate, temperature and initial microstructure on the workability of the Ti alloy were investigated. Based on these experimental results, workability maps for the respective initial microstructures were developed. Results showed that temperature played an important role in the formability of Ti-6Al-4V titanium alloys unlike strain rate. In addition, feasibility study on Multi-Directional Forging (MDF) was performed and positive results were obtained. It was demonstrated that Ti-6Al-4V titanium alloys can undergo severe plastic deformation at lower elevated temperature (400-500 deg. C) and at a higher strain rate of 0.1 s{sup -1}.« less

Experiments and FE-simulations of stretch flanging of DP-steels with different shear cut edge quality

NASA Astrophysics Data System (ADS)

Sigvant, M.; Falk, J.; Pilthammar, J.

2017-09-01

Dual-Phase (DP) steels are today used in the automotive industry due to its large strength to weight ratio. However, the high strength of DP-steel does have a negative impact on the general formability in sheet metal forming. Unfavourable process conditions in the press shop will, on top of this, reduce the formability of DP-steels even more. This paper addresses the problem of edge fracture in stretch flanges in sheet metal parts made of DP-steel. The experimental part involves tests of ten different DP590 and DP780 steel grades with three different shear cut qualities. The influence on the fracture strain of the sample orientation of the shear cut are also studied by facing the burr away or towards the punch and testing samples with the cut edge parallel with the rolling direction and the transverse direction. The strains are measured with an ARAMIS system in each test, together with punch displacement and punch force. All tests are then simulated with AutoFormplus R7 and the results from these simulations are compared with the experimental results in order to find the appropriate failure strain for each combination of supplier, coating, thickness and shear cut quality.

Fabrication process analysis and experimental verification for aluminum bipolar plates in fuel cells by vacuum die-casting

NASA Astrophysics Data System (ADS)

Jin, Chul Kyu; Kang, Chung Gil

2011-10-01

There are various methods for the fabrication of bipolar plates, but these are still limited to machining and stamping processes. High-pressure die casting (HPDC) is an ideal process for the manufacture of bipolar plates This study aims to investigate the formability of bipolar plates for polymer electrolyte membrane fuel cells (PEMFCs) fabricated by vacuum HPDC of an Al-Mg alloy (ALDC6). The cavity of the mold consisted of a thin-walled plate (200 mm × 200 mm × 0.8 mm) with a layer of serpentine channel (50 mm × 50 mm). The location and direction of the channel in the final mold design was determined by computational simulation (MAGMA soft). In addition, simulation results for different conditions of plunger stroke control were compared to those from actual die-casting experiments. Under a vacuum pressure of 35 kPa and for injection speeds of 0.3 and 2.5 m s-1 in the low and high speed regions, respectively, the samples had few casting defects. In addition, the hardness was higher and porosity in microstructure was less than those of the samples made under other injection speed conditions. In case of thin-walled plates, vacuum die casting is beneficial in terms of formability compared to conventional die casting.

Effect of Process Parameters on the Structure and Properties of Galvanized Sheets

NASA Astrophysics Data System (ADS)

Shukla, S. K.; Saha, B. B.; Triathi, B. D.; Avtar, Ram

2010-07-01

The effect of galvanizing parameters on the structure (spangle size and coating microstructure) and properties (formability and corrosion resistance) of galvanized sheets was studied in a hot dip process simulator (HDPS) in a conventional Pb bearing (0.08-0.10%) zinc bath by varying zinc bath Al level (0.10-0.28%), bath temperature (718-743 K), dipping time (1.5-3.5 s), wiping gas flow rate (200-450 lpm), nozzle distance (15-17 mm) and wiping delay time (0.1-2.1 s). Al level in the range of 0.18-0.24% in combination with dipping time of 1.5-2.5 s and bath temperature of 718-733 K results in superior formability ( E cv: ~9.3 mm) of the composite (thickness: 0.8 mm). High post-dip cooling rates (~25 K/s) suppress spangle growth (spangle size: ~2 mm). The spangle size of the GI sheet strongly influences the corrosion rate which increases from 5.8 to 9.2 mpy with a decrease in spangle size from 17.5 to 3 mm. By controlling the Al level (0.20%) in zinc bath and bath temperature (733 K), the corrosion rate of mini-spangle GI sheet can be controlled to a level of 5.5 mpy.

Effect of severe plastic deformation on microstructure of squeeze-cast magnesium alloy AZ31 plate

NASA Astrophysics Data System (ADS)

Fong, Kai Soon; Tan, Ming Jen; Atsushi, Danno; Chua, Beng Wah; Ho, Meng Kwong

2016-10-01

High cost and poor room temperature formability of magnesium alloy sheet are the key factors that limit its application as a feedstock material for press forming. Production of Mg plates by squeeze casting with further processing by severe plastic deformation (SPD) is a potential method to reduce cost and improve formability. In this study, AZ31 Mg plate of dimension 96×96×4 mm was successfully produced by squeeze casting, using a novel melt transfer technique, at a forging force and speed of 180 Ton and 200 mm/sec respectively. The effect of severe plastic deformation (SPD) using groove pressing on the mechanical properties of squeeze-casted Mg plate after partial homogenization was subsequently investigated. Observation of the microstructure after two cycles of groove pressing, under decreasing temperature from 543K to 493K, shows a significant grain refinement from 39 to 4.7 µm. The Vickers hardness increased by approximately 25% from 56 to 74.1 which suggests an improvement in mechanical strength as a result of both the grain refinement and work hardening. The result shows that squeeze casting combined with groove pressing is potentially an effective method for preparation of thin magnesium alloy plate with fine-grained structure and improved mechanical properties.

Novel twin-roll-cast Ti/Al clad sheets with excellent tensile properties.

PubMed

Kim, Dae Woong; Lee, Dong Ho; Kim, Jung-Su; Sohn, Seok Su; Kim, Hyoung Seop; Lee, Sunghak

2017-08-14

Pure Ti or Ti alloys are recently spot-lighted in construction industries because they have excellent resistance to corrosions, chemicals, and climates as well as various coloring characteristics, but their wide applications are postponed by their expensiveness and poor formability. We present a new fabrication process of Ti/Al clad sheets by bonding a thin Ti sheet on to a 5052 Al alloy melt during vertical-twin-roll casting. This process has merits of reduced production costs as well as improved tensile properties. In the as-twin-roll-cast clad sheet, the homogeneously cast microstructure existed in the Al alloy substrate side, while the Ti/Al interface did not contain any reaction products, pores, cracks, or lateral delamination, which indicated the successful twin-roll casting. When this sheet was annealed at 350 °C~600 °C, the metallurgical bonding was expanded by interfacial diffusion, thereby leading to improvement in tensile properties over those calculated by a rule of mixtures. The ductility was also improved over that of 5052-O Al alloy (25%) or pure Ti (25%) by synergic effect of homogeneous deformation due to excellent Ti/Al bonding. This work provides new applications of Ti/Al clad sheets to lightweight-alloy clad sheets requiring excellent formability and corrosion resistance as well as alloy cost saving.

Forming characteristics of artificial aging Al-Mg-Si-Cu sheet alloys

NASA Astrophysics Data System (ADS)

Klos, Artur; Kellner, Sven; Wortberg, Daniel; Walter, Philipp; Bassi, Corrado; Merklein, Marion

2017-10-01

AA6111 is a commonly used aluminum alloy for body-in-white (BIW) components with good bake-hardening response, high strength and excellent formability. For industrial applications various process strategies are considered to reach strength of about 250 MPa in the final body part with that type of alloy. The purpose of this paper is to discuss recent process strategies of high-strength AA6111 sheets to evaluate the forming characteristics, precipitation kinetics dissolution and mechanical properties in the final condition. The forming behavior is investigated by four potential process chains after single-stage or multi-stage heat treatment including T4 (pre-aged at > 80 °C after quenching), T61 (T4 + artificial aged at 120-150 °C for 10-18 h), T6 (T4 + artificial aged at 180-220°C up to 12 h) and PFHT (T4 + post form heat treatment at 205°C for 30 min). The experimental input for characterization of the formability consists of tensile tests, bending tests and drawing tests. Differential Scanning Calorimetry (DSC) is used, to correlate the forming behavior with the precipitation distribution in the advanced stages of aging. The study shows that the forming behavior is strongly dependent on the condition the alloy.

Developing an experimental case in aluminium foils 1100 to determine the maximum angle of formability in a piece by Dieless-SPIF process

NASA Astrophysics Data System (ADS)

Gabriel, Paramo; Adrian, Benitez

2014-07-01

Incremental sheet forming by the method of single point incremental forming Dieless-SPIF, is a widely studied process, experimented and developed in countries with high manufacturing technologies, with friendly costs when the productive configuration in a productivity system is based in small production batches. United states, United kingdom and France lead this type of studies and cases, developing various proof with experimental geometries, different from the national environment such as Colombia, Bolivia, Chile, Ecuador and Peru where this process where discretely studied. Previously mentioned, it pretends develop an experimental case of a particular geometry, identifying the maximum formability angle of material permissible for the forming of a piece in one pass, the analysis of forming limit curve (FLC), with the objective to emphasizes in this innovative method based in CAD-CAM technologies, compare with other analogous process of deformation sheet metal like embossing, take correct decisions about the viability and applicability of this process (Dieless) in a particular industrial piece, which responses to the necessities of productive configurations mentioned and be highly taken like a manufacturing alternative to the other conventional process of forming sheet metal like embossing, for systems with slow batches production.

Novel Approach for Prediction of Localized Necking in Case of Nonlinear Strain Paths

NASA Astrophysics Data System (ADS)

Drotleff, K.; Liewald, M.

2017-09-01

Rising customer expectations regarding design complexity and weight reduction of sheet metal components alongside with further reduced time to market implicate increased demand for process validation using numerical forming simulation. Formability prediction though often is still based on the forming limit diagram first presented in the 1960s. Despite many drawbacks in case of nonlinear strain paths and major advances in research in the recent years, the forming limit curve (FLC) is still one of the most commonly used criteria for assessing formability of sheet metal materials. Especially when forming complex part geometries nonlinear strain paths may occur, which cannot be predicted using the conventional FLC-Concept. In this paper a novel approach for calculation of FLCs for nonlinear strain paths is presented. Combining an interesting approach for prediction of FLC using tensile test data and IFU-FLC-Criterion a model for prediction of localized necking for nonlinear strain paths can be derived. Presented model is purely based on experimental tensile test data making it easy to calibrate for any given material. Resulting prediction of localized necking is validated using an experimental deep drawing specimen made of AA6014 material having a sheet thickness of 1.04 mm. The results are compared to IFU-FLC-Criterion based on data of pre-stretched Nakajima specimen.

Distribution of nickel after modified nitinol stent implantation in animals

NASA Astrophysics Data System (ADS)

Chepeleva, E.; Sergeevichev, D.; Lotkov, A.; Kashin, O.; Korobeynikov, A.; Kozyr, K.; Baystrukov, V.; Zubarev, D.; Kretov, E.; Pokushalov, E.

2017-09-01

Intravascular stenting of arteries in atherosclerotic lesions is one of the most frequently performed procedures in cardiovascular surgery today. Most stents are made of various stainless-steel alloys and other metals (such as nitinol). Nitinol is a biocompatible, superplastic and corrosion resistant material with an important feature of shape memory. However, the composition of this alloy includes nickel, which shows toxicity to the kidneys, liver, lungs, heart and other organs when it accumulates in the organism. In this research we investigated the nickel content in serum, urine and hair of the laboratory animals after implantation of nitinol stents treated with plasma ionic surface modification by silicon.

Design of cryogenic tanks for space vehicles shell structures analytical modeling

NASA Technical Reports Server (NTRS)

Copper, Charles; Mccarthy, K.; Pilkey, W. D.; Haviland, J. K.

1991-01-01

The initial objective was to study the use of superplastically formed corrugated hat section stringers and frames in place of integrally machined stringers over separate frames for the tanks of large launch vehicles subjected to high buckling loads. The ALS was used as an example. The objective of the follow-on project was to study methods of designing shell structures subjected to severe combinations of structural loads and thermal gradients, with emphasis on new combinations of structural arrangements and materials. Typical applications would be to fuselage sections of high speed civil transports and to cryogenic tanks on the National Aerospace Plane.

The influence of deformation-induced residual stresses on the post-forming tensile stress/strain behavior of dual-phase steels

NASA Astrophysics Data System (ADS)

Hance, Brandon Michael

It was hypothesized that, in dual-phase (DP) steels, strain partitioning between ferrite (alpha) and martensite (alpha') during deformation results in a distribution of post-deformation residual stresses that, in turn, affects the subsequent strength, work hardening behavior and formability when the strain path is changed. The post-forming deformation-induced residual stress state was expected to depend upon the microstructure, the amount of strain and the prestrain path. The primary objective of this research program was to understand the influence of deformation-induced residual stresses on the post-forming tensile stress/strain behavior of DP steels. Three commercially produced sheet steels were considered in this analysis: (1) a DP steel with approximately 15 vol. % martensite, (2) a conventional high-strength, low-alloy (HSLA) steel, and (3) a conventional, ultra-low-carbon interstitial-free (IF) steel. Samples of each steel were subjected to various prestrain levels in various plane-stress forming modes, including uniaxial tension, plane strain and balanced biaxial stretching. Neutron diffraction experiments confirmed the presence of large post-forming deformation-induced residual stresses in the ferrite phase of the DP steel. The deformation-alphainduced residual stress state varied systematically with the prestrain mode, where the principal residual stress components are proportional to the principal strain components of the prestrain mode, but opposite in sign. For the first time, and by direct experimental correlation, it was shown that deformation-induced residual stresses greatly affect the post-forming tensile stress/strain behavior of DP steels. As previously reported in the literature, the formability (residual tensile ductility) of the IF steel and the HSLA steel was adversely affected by strain path changes. The DP steel presents a formability advantage over the conventional IF and HSLA steels, and is expected to be particularly well suited for complex forming operations that involve abrupt strain path changes. Deformation-induced residual stresses were measured in the IF steel and the HSLA steel; however, the magnitudes of which are such that post-forming tensile stress/strain behavior was not significantly affected. Considering the vast differences in mechanical properties, microstructure, and composition, the IF steel and the HSLA steel showed remarkably similar post-forming tensile stress/strain behavior for all prestrain modes considered.

The feasibility of producing aluminum-lithium structures for cryogenic tankage applications by laser beam welding

NASA Technical Reports Server (NTRS)

Martukanitz, R. P.; Lysher, K. G.

1993-01-01

Aluminum-lithium alloys exhibit high strength, high elastic modulus, and low density as well as excellent cryogenic mechanical properties making them ideal material candidates for cryogenic tanks. NASA has proposed the use of 'built-up' structure for panels fabricated into cryogenic tanks replacing current conventional machining. Superplastically formed stiffeners would be joined to sheet (tank skin) that had been roll formed to the radius of the tank in order to produce panels. Aluminum-lithium alloys of interest for producing the built-up structure include alloy 2095-T6 stiffeners to 2095-T8 sheet and alloy 8090-T6 stiffeners to 2090-T83 sheet. Laser welding, with comparable joint properties, offers the following advantages over conventional welding: higher production rates, minimal degradation within the heat affected zones, and full process automation. This study established process parameters for laser beam welding, mechanical property determinations, metallographic characterization, and fabrication of prototype panels. Tensile tests representing partial penetration of the skin alloys provided joint efficiencies between 65 and 77 percent, depending upon alloy and degree of penetration. Results of tension shear tests of lap welds indicated that the combination of 2095-T6 to 2090-T8 exhibited significantly higher weld shear strength at the interface in comparison to welds of 8090-T6 to 2090-T83. The increased shear strength associated with 2095 is believed to be due to the alloy's ability to precipitation strengthening (naturally age) after welding.

The effect of solidification rate on the formability of nickel aluminide containing iron and boron

NASA Technical Reports Server (NTRS)

Carro, G.; Flanagan, W. F.

1987-01-01

Following reports that rapid solidification improves the ductility of some nickel aluminides, an investigation has been conducted of the possibility of additional improvement in a nickel aluminide containing both Fe and B. Free fall-solidified and free fall/splat-quenched samples similar to those producible under microgravity conditions in space were prepared, and their microstructure was characterized. Attention is given to the preliminary results of tests quantitatively measuring mechanical properties.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Zou, Yun; Zhang, Lehao; Li, Yang

Limitations of strength and formability are the major obstacles to the industrial application of magnesium alloys. Here, we demonstrate, by producing the duplex phases and fine intermetallic particles in composition-optimized superlight Mg-Li-Al alloys, a unique approach to simultaneously improve the comprehensive mechanical properties (a strength-ductility balance). In conclusion, the phase components and microstructures, including the size, morphology, and distribution of precipitated-intermetallic particles can be optimized by tuning the Li content, which strongly influences the work-hardening behavior and tension-compression yield asymmetry.

The Home Stretch Almost! Science with the Hubble and James Webb Space Telescope V

NASA Technical Reports Server (NTRS)

Ochs, Bill

2017-01-01

JWST has Made tremendous progress in the last few years. JWST Is fully immersed in integration and test, but testing JWST is a formable challenge. JWST's size, complexity, and cryogenic characteristics require a multifaceted test plan to verify mission readiness. Each of these tests are opportunities to uncover issues which must be corrected to be able to move forward. All observatory control, science planning, and science data processing operational systems are on schedule.?

Bias extension test on a bi-axial non-crimp fabric powdered with a non-reactive binder system

NASA Astrophysics Data System (ADS)

Pourtier, Jean; Duchamp, Boris; Kowalski, Maxime; Legrand, Xavier; Wang, Peng; Soulat, Damien

2018-05-01

In this communication, we investigated the effects of a chemical non-reactive binder system (powder) on the formability of NCF. Those influences are evaluated for two different of bi-axial NCF structures tested in a range of temperature [20°C - 140°] during bias extension tests (Fig. 1). This analyze is based on the study of force in function of deformation modes (slipping effects and shear angle field).

Metamodeling and optimization of the THF process with pulsating pressure

NASA Astrophysics Data System (ADS)

Bucconi, Marco; Strano, Matteo

2018-05-01

Tube hydroforming is a process used in various applications to form the tube in a desired complex shape, by combining the use of internal pressure, which provides the required stress to yield the material, and axial feeding, which helps the material to flow towards the bulging zone. In many studies it has been demonstrated how wrinkling and bursting defects can be severely reduced by means of a pulsating pressure, and how the so-called hammering hydroforming enhances the formability of the material. The definition of the optimum pressure and axial feeding profiles represent a daunting challenge in the designing phase of the hydroforming operation of a new part. The quality of the formed part is highly dependent on the amplitude and the peak value of the pulsating pressure, along with the axial stroke. In this paper, a research is reported, conducted by means of explicit finite element simulations of a hammering THF operation and metamodeling techniques aimed at optimizing the process parameters for the production of a complex part. The improved formability is explored for different factors and an optimization strategy is used to determine the most convenient pressure and axial feed profile curves for the hammering THF process of the examined part. It is shown how the pulsating pressure allows the minimization of the energy input in the process, still respecting final quality requirements.

The effect of oxygen plasma pretreatment and incubation in modified simulated body fluids on the formation of bone-like apatite on poly(lactide-co-glycolide) (70/30).

PubMed

Qu, Xue; Cui, Wenjin; Yang, Fei; Min, Changchun; Shen, Hong; Bei, Jianzhong; Wang, Shenguo

2007-01-01

In this study, biodegradable poly(lactide-co-glycolide) (PLGA) (70/30) films and scaffolds were first treated with oxygen plasma and then incubated in a modified simulated body fluid 1.5SBF0 to prepare a bone-like apatite layer. The formation of the apatite and its influence on osteoblast-like cells growth were investigated. It was found that the bone-like apatite formability of PLGA(70/30) was enhanced by plasma pretreatment. The changes of surface chemistry and surface topography induced by oxygen plasma treatment were both effective for apatite formation. The apatite formability increased with increasing plasma-treating time. Under a treating condition of 20 W for 30 min, oxygen plasma treatment could penetrate into the inner scaffold. After 6 days incubation, the apatite formed in plasma-treated scaffold was better distributed than in untreated scaffold, and the weight and mechanical strength of the plasma-treated scaffold were both enhanced. Compared with PLGA(70/30), the apatite layer formed on oxygen plasma-treated PLGA(70/30) surface enhanced adhesion and proliferation of OCT-1 osteoblast-like cell, but had no significant effect on cell's ALP activity at day 7. A prolonged investigation is being in process to further verify the bone-like apatite effects on osteogenic differentiation.

Forming-Limit Diagrams for Magnesium AZ31B and ZEK100 Alloy Sheets at Elevated Temperatures

NASA Astrophysics Data System (ADS)

Antoniswamy, Aravindha R.; Carpenter, Alexander J.; Carter, Jon T.; Hector, Louis G.; Taleff, Eric M.

2013-11-01

Modern design and manufacturing methodologies for magnesium (Mg) sheet panels require formability data for use in computer-aided design and computer-aided engineering tools. To meet this need, forming-limit diagrams (FLDs) for AZ31B and ZEK100 wrought Mg alloy sheets were developed at elevated temperatures for strain rates of 10-3 and 10-2 s-1. The elevated temperatures investigated range from 250 to 450 °C for AZ31B and 300 to 450 °C for ZEK100. The FLDs were generated using data from uniaxial tension, biaxial bulge, and plane-strain bulge tests, all carried out until specimen rupture. The unique aspect of this study is that data from materials with consistent processing histories were produced using consistent testing techniques across all test conditions. The ZEK100 alloy reaches greater major true strains at rupture, by up to 60%, than the AZ31B alloy for all strain paths at all temperatures and strain rates examined. Formability limits decrease only slightly with a decrease in temperature, less than 30% decrease for AZ31B and less than 35% decrease for ZEK100 as the temperature decreases from 450 to 300 °C. This suggests that forming processes at 250-300 °C are potentially viable for manufacturing complex Mg components.

Rapid Freeform Sheet Metal Forming: Technology Development and System Verification

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kiridena, Vijitha; Verma, Ravi; Gutowski, Timothy

The objective of this project is to develop a transformational RApid Freeform sheet metal Forming Technology (RAFFT) in an industrial environment, which has the potential to increase manufacturing energy efficiency up to ten times, at a fraction of the cost of conventional technologies. The RAFFT technology is a flexible and energy-efficient process that eliminates the need for having geometry-specific forming dies. The innovation lies in the idea of using the energy resource at the local deformation area which provides greater formability, process control, and process flexibility relative to traditional methods. Double-Sided Incremental Forming (DSIF), the core technology in RAFFT, ismore » a new concept for sheet metal forming. A blank sheet is clamped around its periphery and gradually deformed into a complex 3D freeform part by two strategically aligned stylus-type tools that follow a pre-described toolpath. The two tools, one on each side of the blank, can form a part with sharp features for both concave and convex shapes. Since deformation happens locally, the forming force at any instant is significantly decreased when compared to traditional methods. The key advantages of DSIF are its high process flexibility, high energy-efficiency, low capital investment, and the elimination of the need for massive amounts of die casting and machining. Additionally, the enhanced formability and process flexibility of DSIF can open up design spaces and result in greater weight savings.« less

Stamping an AA5754 Train Window Panel with High Dent Resistance Using Locally Annealed Blanks

NASA Astrophysics Data System (ADS)

Piccininni, A.; Guglielmi, P.; Lo Franco, A.; Palumbo, G.

2017-09-01

The warm stamping of an AA5754-H32 window panel for railway vehicles applications has been proposed in the present work. The adoption of increased working temperatures can be surely considered the most effective solution for this alloy to overcome the limited material formability at room temperature [Palumbo et al. “Warm Forming of an AA5754 Component for Railway Vehicle Applications”, Procedia Engineering, Vol. 183, 2017, Pages 351-356] but, in order to improve the overall dent resistance of the component, the initial wrought conditions have been chosen in the present work. The manufacturing of the window panel was thus subdivided into a preliminary local heat treatment (assumed to be performed by laser) to anneal the material and a subsequent warm stamping step using heated tools. The best combination of temperature and holding time able to produce the annealing of the investigated alloy was determined using the physical simulator Gleeble 3180. On the contrary, the warm forming step was designed by means of thermo-mechanical simulations: in order to model the AA5754-H32 blank with annealed regions, an extensive experimental campaign (tensile and formability tests) was conducted using specimens in the annealed (H111) and in the wrought (H32) conditions. Through the numerical approach it was thus possible define: (i) the extent of the annealed regions; (ii) the punch speed to get a sound component.

New Forming Technologies for Autobody at POSCO

NASA Astrophysics Data System (ADS)

Lee, Hong-Woo; Cha, Myung-Hwan; Choi, Byung-Keun; Kim, Gyo-Sung; Park, Sung-Ho

2011-08-01

As development of car body with light weight and enhanced safety became one of the hottest issues in the auto industry, the advanced high strength steels have been broadly applied to various automotive parts over the last few years. Corresponding to this trend, POSCO has developed various types of cold and hot rolled AHSSs such as DP, TRIP, CP and FB, and continues to develop new types of steel in order to satisfy the requirement of OEMs more extensively. To provide optimal technical supports to customers, POSCO has developed more advanced EVI concept, which includes the concept of CE/SE, VA/VE, VI and PP as well as the conventional EVI strategy. To realize this concept, POSCO not only supports customers with material data, process guideline, and evaluation of formability, weld-ability, paint-ability and performance but also provides parts or sub-assemblies which demand highly advanced technologies. Especially, to accelerate adoption of AHSS in autobody, POSCO has tried to come up with optimal solutions to AHSS forming. Application of conventional forming technologies has been restricted more and more by relatively low formability of AHSS with high tensile-strength. To overcome the limitation in the forming, POSCO has recently developed new forming technologies such as hydro-forming, hot press forming, roll forming and form forming. In this paper, tailored strength HPF, hydroformed torsion beam axle and multi-directional roll forming are introduced as examples of new forming technologies.

Experimental and Numerical Studies on Fiber Deformation and Formability in Thermoforming Process Using a Fast-Cure Carbon Prepreg: Effect of Stacking Sequence and Mold Geometry.

PubMed

Bae, Daeryeong; Kim, Shino; Lee, Wonoh; Yi, Jin Woo; Um, Moon Kwang; Seong, Dong Gi

2018-05-21

A fast-cure carbon fiber/epoxy prepreg was thermoformed against a replicated automotive roof panel mold (square-cup) to investigate the effect of the stacking sequence of prepreg layers with unidirectional and plane woven fabrics and mold geometry with different drawing angles and depths on the fiber deformation and formability of the prepreg. The optimum forming condition was determined via analysis of the material properties of epoxy resin. The non-linear mechanical properties of prepreg at the deformation modes of inter- and intra-ply shear, tensile and bending were measured to be used as input data for the commercial virtual forming simulation software. The prepreg with a stacking sequence containing the plain-woven carbon prepreg on the outer layer of the laminate was successfully thermoformed against a mold with a depth of 20 mm and a tilting angle of 110°. Experimental results for the shear deformations at each corner of the thermoformed square-cup product were compared with the simulation and a similarity in the overall tendency of the shear angle in the path at each corner was observed. The results are expected to contribute to the optimization of parameters on materials, mold design and processing in the thermoforming mass-production process for manufacturing high quality automotive parts with a square-cup geometry.

Experimental and Numerical Studies on Fiber Deformation and Formability in Thermoforming Process Using a Fast-Cure Carbon Prepreg: Effect of Stacking Sequence and Mold Geometry

PubMed Central

Bae, Daeryeong; Kim, Shino; Lee, Wonoh; Yi, Jin Woo; Um, Moon Kwang; Seong, Dong Gi

2018-01-01

A fast-cure carbon fiber/epoxy prepreg was thermoformed against a replicated automotive roof panel mold (square-cup) to investigate the effect of the stacking sequence of prepreg layers with unidirectional and plane woven fabrics and mold geometry with different drawing angles and depths on the fiber deformation and formability of the prepreg. The optimum forming condition was determined via analysis of the material properties of epoxy resin. The non-linear mechanical properties of prepreg at the deformation modes of inter- and intra-ply shear, tensile and bending were measured to be used as input data for the commercial virtual forming simulation software. The prepreg with a stacking sequence containing the plain-woven carbon prepreg on the outer layer of the laminate was successfully thermoformed against a mold with a depth of 20 mm and a tilting angle of 110°. Experimental results for the shear deformations at each corner of the thermoformed square-cup product were compared with the simulation and a similarity in the overall tendency of the shear angle in the path at each corner was observed. The results are expected to contribute to the optimization of parameters on materials, mold design and processing in the thermoforming mass-production process for manufacturing high quality automotive parts with a square-cup geometry. PMID:29883413

Tailorable Burning Behavior of Ti14 Alloy by Controlling Semi-Solid Forging Temperature.

PubMed

Chen, Yongnan; Yang, Wenqing; Zhan, Haifei; Zhang, Fengying; Huo, Yazhou; Zhao, Yongqing; Song, Xuding; Gu, Yuantong

2016-08-16

Semi-solid processing (SSP) is a popular near-net-shape forming technology for metals, while its application is still limited in titanium alloy mainly due to its low formability. Recent works showed that SSP could effectively enhance the formability and mechanical properties of titanium alloys. The processing parameters such as temperature and forging rate/ratio, are directly correlated with the microstructure, which endow the alloy with different chemical and physical properties. Specifically, as a key structural material for the advanced aero-engine, the burn resistant performance is a crucial requirement for the burn resistant titanium alloy. Thus, this work aims to assess the burning behavior of Ti14, a kind of burn resistant alloy, as forged at different semi-solid forging temperatures. The burning characteristics of the alloy are analyzed by a series of burning tests with different burning durations, velocities, and microstructures of burned sample. The results showed that the burning process is highly dependent on the forging temperature, due to the fact that higher temperatures would result in more Ti₂Cu precipitate within grain and along grain boundaries. Such a microstructure hinders the transport of oxygen in the stable burning stage through the formation of a kind of oxygen isolation Cu-enriched layer under the burn product zone. This work suggests that the burning resistance of the alloy can be effectively tuned by controlling the temperature during the semi-solid forging process.

The interaction between short-term heat-treatment and the formability of an Al-Mg-Si alloy regarding deep drawing processes

NASA Astrophysics Data System (ADS)

Machhammer, M.; Sommitsch, C.

2016-11-01

Research conducted in recent years has shown that heat-treatable Al-Mg-Si alloys (6xxx) have great potential concerning the design of lightweight car bodies. Compared to conventional deep drawing steels the field of application is limited by a lower formability. In order to minimize the disadvantage of a lower drawability a short-term heat-treatment (SHT) can be applied before the forming process. The SHT, conducted in selected areas on the initial blank, leads to a local reduction of strength aiming at the decrease of critical stress during the deep drawing process. For the successful procedure of the SHT a solid knowledge about the crucial process parameters such as the design of the SHT layout, the SHT process time and the maximum SHT temperature are urgently required. It also should be noted that the storage time between the SHT and the forming processes affects the mechanical properties of the SHT area. In this paper, the effect of diverse SHT process parameters and various storage time-frames on the major and minor strain situation of a deep drawn part is discussed by the evaluation of the forming limit diagram. For the purpose of achieving short heating times and a homogenous temperature distribution a one side contact heating tool has been used for the heat treatment in this study.

Dislocation Strengthening without Ductility Trade-off in Metastable Austenitic Steels

PubMed Central

Liu, Jiabin; Jin, Yongbin; Fang, Xiaoyang; Chen, Chenxu; Feng, Qiong; Liu, Xiaowei; Chen, Yuzeng; Suo, Tao; Zhao, Feng; Huang, Tianlin; Wang, Hongtao; Wang, Xi; Fang, Youtong; Wei, Yujie; Meng, Liang; Lu, Jian; Yang, Wei

2016-01-01

Strength and ductility are mutually exclusive if they are manifested as consequence of the coupling between strengthening and toughening mechanisms. One notable example is dislocation strengthening in metals, which invariably leads to reduced ductility. However, this trend is averted in metastable austenitic steels. A one-step thermal mechanical treatment (TMT), i.e. hot rolling, can effectively enhance the yielding strength of the metastable austenitic steel from 322 ± 18 MPa to 675 ± 15 MPa, while retaining both the formability and hardenability. It is noted that no boundaries are introduced in the optimized TMT process and all strengthening effect originates from dislocations with inherited thermal stability. The success of this method relies on the decoupled strengthening and toughening mechanisms in metastable austenitic steels, in which yield strength is controlled by initial dislocation density while ductility is retained by the capability to nucleate new dislocations to carry plastic deformation. Especially, the simplicity in processing enables scaling and industrial applications to meet the challenging requirements of emissions reduction. On the other hand, the complexity in the underlying mechanism of dislocation strengthening in this case may shed light on a different route of material strengthening by stimulating dislocation activities, rather than impeding motion of dislocations. PMID:27739481

Aluminum 2195 T8 Gore Development for Space Launch System Core and Upper Stage

NASA Technical Reports Server (NTRS)

Volz, Martin

2015-01-01

Gores are pie-shaped panels that are welded together to form the dome ends of rocket fuel tanks as shown in figure 1. Replacing aluminum alloy 2219 with aluminum (Al)-lithium (Li) alloy 2195 as the Space Launch System (SLS) cryogenic tank material would save enormous amounts of weight. In fact, it has been calculated that simply replacing Al 2219 gores with Al 2195 gores on the SLS core stage domes could save approximately 3,800 pound-mass. This is because the Al-Li 2195 alloy exhibits both higher mechanical properties and lower density than the SLS baseline Al 2219 alloy. Indeed, the known advantages of Al 2195 led to its use as a replacement for Al 2219 in the shuttle external tank program. The required thicknesses of Al 2195 gores for either SLS core stage tanks or upper stage tanks will depend on the specific design configurations. The required thicknesses or widths may exceed the current experience base in the manufacture of such gores by the stretch-forming process. Accordingly, the primary objective of this project was to enhance the formability of Al 2195 by optimizing the heat treatment and stretch-forming process for gore thicknesses up to 0.75 inches, which envelop the maximum expected gore thicknesses for SLS tank configurations.

Dislocation Strengthening without Ductility Trade-off in Metastable Austenitic Steels

NASA Astrophysics Data System (ADS)

Liu, Jiabin; Jin, Yongbin; Fang, Xiaoyang; Chen, Chenxu; Feng, Qiong; Liu, Xiaowei; Chen, Yuzeng; Suo, Tao; Zhao, Feng; Huang, Tianlin; Wang, Hongtao; Wang, Xi; Fang, Youtong; Wei, Yujie; Meng, Liang; Lu, Jian; Yang, Wei

2016-10-01

Strength and ductility are mutually exclusive if they are manifested as consequence of the coupling between strengthening and toughening mechanisms. One notable example is dislocation strengthening in metals, which invariably leads to reduced ductility. However, this trend is averted in metastable austenitic steels. A one-step thermal mechanical treatment (TMT), i.e. hot rolling, can effectively enhance the yielding strength of the metastable austenitic steel from 322 ± 18 MPa to 675 ± 15 MPa, while retaining both the formability and hardenability. It is noted that no boundaries are introduced in the optimized TMT process and all strengthening effect originates from dislocations with inherited thermal stability. The success of this method relies on the decoupled strengthening and toughening mechanisms in metastable austenitic steels, in which yield strength is controlled by initial dislocation density while ductility is retained by the capability to nucleate new dislocations to carry plastic deformation. Especially, the simplicity in processing enables scaling and industrial applications to meet the challenging requirements of emissions reduction. On the other hand, the complexity in the underlying mechanism of dislocation strengthening in this case may shed light on a different route of material strengthening by stimulating dislocation activities, rather than impeding motion of dislocations.

Dislocation Strengthening without Ductility Trade-off in Metastable Austenitic Steels.

PubMed

Liu, Jiabin; Jin, Yongbin; Fang, Xiaoyang; Chen, Chenxu; Feng, Qiong; Liu, Xiaowei; Chen, Yuzeng; Suo, Tao; Zhao, Feng; Huang, Tianlin; Wang, Hongtao; Wang, Xi; Fang, Youtong; Wei, Yujie; Meng, Liang; Lu, Jian; Yang, Wei

2016-10-14

Strength and ductility are mutually exclusive if they are manifested as consequence of the coupling between strengthening and toughening mechanisms. One notable example is dislocation strengthening in metals, which invariably leads to reduced ductility. However, this trend is averted in metastable austenitic steels. A one-step thermal mechanical treatment (TMT), i.e. hot rolling, can effectively enhance the yielding strength of the metastable austenitic steel from 322 ± 18 MPa to 675 ± 15 MPa, while retaining both the formability and hardenability. It is noted that no boundaries are introduced in the optimized TMT process and all strengthening effect originates from dislocations with inherited thermal stability. The success of this method relies on the decoupled strengthening and toughening mechanisms in metastable austenitic steels, in which yield strength is controlled by initial dislocation density while ductility is retained by the capability to nucleate new dislocations to carry plastic deformation. Especially, the simplicity in processing enables scaling and industrial applications to meet the challenging requirements of emissions reduction. On the other hand, the complexity in the underlying mechanism of dislocation strengthening in this case may shed light on a different route of material strengthening by stimulating dislocation activities, rather than impeding motion of dislocations.

Experimental investigation of anisotropy evolution of AZ31 magnesium alloy sheets under tensile loading

NASA Astrophysics Data System (ADS)

Tari, D. Ghaffari; Worswick, M. J.

2011-05-01

Increasing demand for lighter final products has created new opportunities for the application of new light weight materials. Due to high strength to density ratio and good magnetic resistance properties, magnesium alloys are good candidates to replace steel and aluminum for same application. However, limited numbers of active slip deformation mechanisms, result in a decreased formability at room temperature. Furthermore, wrought magnesium alloys have an initial crystallographic texture, remained from the prior rolling operations, which makes them highly anisotropic. In this paper, tensile tests are performed at room temperature and 200° C at different strain rates and orientations relative to the rolling direction, including rolling, 30°, 45°, 60° and transverse orientation. The strain rates adopted for these experiments varied from 0.001 to 1.0. The testing results show the effect of temperature on the strain rate sensitivity of AZ31 sheets. The extent of deformation is continuously recorded using two separate high temperature extensometers. The results of testing show an increase in the r-values with the plastic deformation. The strain rate sensitivity of AZ31 increased as the temperature was elevated. At higher strain rates the measured r-values are larger and the slope of its evolution with the plastic strain is steeper.

Materials Research for High Speed Civil Transport and Generic Hypersonics-Metals Durability

NASA Technical Reports Server (NTRS)

Schulz, Paul; Hoffman, Daniel

1996-01-01

This report covers a portion of an ongoing investigation of the durability of titanium alloys for the High Speed Civil Transport (HSCT). Candidate alloys need to possess an acceptable combination of properties including strength and toughness as well as fatigue and corrosion resistance when subjected to the HSCT operational environment. These materials must also be capable of being processed into required product forms while maintaining their properties. Processing operations being considered for this airplane include forming, welding, adhesive bonding, and superplastic forming with or without diffusion bonding. This program was designed to develop the material properties database required to lower the risk of using advanced titanium alloys on the HSCT.

Transformation process for production of ultrahigh carbon steels and new alloys

DOEpatents

Strum, M.J.; Goldberg, A.; Sherby, O.D.; Landingham, R.L.

1995-08-29

Ultrahigh carbon steels with superplastic properties are produced by heating a steel containing ferrite and carbide phases to a soaking temperature approximately 50 C above the A{sub 1} transformation temperature, soaking the steel above the A{sub 1} temperature for a sufficient time that the major portion of the carbides dissolve into the austenite matrix, and then cooling the steel in a controlled manner within predetermined limits of cooling rate or transformation temperature, to obtain a steel having substantially spheroidal carbides. New alloy compositions contain aluminum and solute additions which promote the formation of a fine grain size and improve the resistance of the carbides to coarsening at the forming temperature. 9 figs.

Transformation process for production of ultrahigh carbon steels and new alloys

DOEpatents

Strum, Michael J.; Goldberg, Alfred; Sherby, Oleg D.; Landingham, Richard L.

1995-01-01

Ultrahigh carbon steels with superplastic properties are produced by heating a steel containing ferrite and carbide phases to a soaking temperature approximately 50.degree. C. above the A.sub.1 transformation temperature, soaking the steel above the A.sub.1 temperature for a sufficient time that the major portion of the carbides dissolve into the austenite matrix, and then cooling the steel in a controlled manner within predetermined limits of cooling rate or transformation temperature, to obtain a steel having substantially spheroidal carbides. New alloy compositions contain aluminum and solute additions which promote the formation of a fine grain size and improve the resistance of the carbides to coarsening at the forming temperature.

Application of powder metallurgy to an advanced-temperature nickel-base alloy, NASA-TRW 6-A

NASA Technical Reports Server (NTRS)

Freche, J. C.; Ashbrook, R. L.; Waters, W. J.

1971-01-01

Bar stock of the NASA-TRW 6-A alloy was made by prealloyed powder techniques and its properties evaluated over a range of temperatures. Room temperature ultimate tensile strength was 1894 MN/sq m (274 500 psi). The as-extruded powder product showed substantial improvements in strength over the cast alloy up to 649 C (1200 F) and superplasticity at 1093 C (2000 F). Both conventional and autoclave heat treatments were applied to the extruded powder product. The conventional heat treatment was effective in increasing rupture life at 649 and 704 C (1200 and 1300 F); the autoclave heat treatment, at 760 and 816 C (1400 and 1500 F).

Sliding inclusions and their applications

DOE Office of Scientific and Technical Information (OSTI.GOV)

Mura, T.

It is found that when an ellipsoidal inclusion undergoes a shear eigenstrain and the inclusion is free to slip along the interface, the stress field vanishes everywhere in the inclusion and the matrix. It is assumed in the analysis that the inclusion interface cannot sustain any shear traction. There exists a shear deformation which transforms an ellipsoid into the identical ellipsoid without changing its orientation (ellipsoid invariant transformation). Therefore, no resistance for shear deformation is expected. This may be a characteristic of deformation seen in superplasticity alloys and granular materials. The theory is valid even for large deformations when incrementalmore » strains (or strain rates) are considered instead of strains themselves.« less

Superplastic Behaviour of AZ61-F Magnesium Composite Materials

NASA Astrophysics Data System (ADS)

Besterci, Michal; Sülleiová, Katarína; Velgosová, Oksana; Balloková, Beáta; Huang, S.-J.

2017-03-01

Deformation of AZ61-F magnesium alloys with 1 wt % of Al2O3 phase was tested at different temperatures and different strain rates. It was shown that at temperatures 473-523 K and the highest strain rate applied from 1×10-2 s-1 to 1×10-4 s-1, a significant ductility growth was observed. The grain size of 0.6-0.8 μm was reached by severe plastic deformations by means of equal channel angular pressing (ECAP). Secondary Mg17Al12 and Al2O3 phases were identified. Maximum strain was gained at temperature of 473 K and strain rate of 1×10-4 s-1.

Numerical Implementation of Ice Rheology for Europa's Shell

NASA Technical Reports Server (NTRS)

Barr, A. C.; Pappalardo, R. T.

2004-01-01

We present a discussion of approximations to the temperature dependent part of the rheology of ice. We have constructed deformation maps using the superplastic rheology of Goldsby & Kohlstedt and find that the rheologies that control convective flow in the Europa's are likely grain boundary sliding and basal slip for a range of grain sizes 0.1 mm < d < 1 cm. We compare the relative merits of two different approximations to the temperature dependence of viscosity and argue that for temperature ranges appropriate to Europa, implementing the non-Newtonian, lab-derived flow law directly is required to accurately judge the onset of convection in the ice shell and temperature gradient in the near-surface ice.

Abnormal Grain Growth Suppression in Aluminum Alloys

NASA Technical Reports Server (NTRS)

Hales, Stephen J. (Inventor); Claytor, Harold Dale (Inventor); Alexa, Joel A. (Inventor)

2015-01-01

The present invention provides a process for suppressing abnormal grain growth in friction stir welded aluminum alloys by inserting an intermediate annealing treatment ("IAT") after the welding step on the article. The IAT may be followed by a solution heat treatment (SHT) on the article under effectively high solution heat treatment conditions. In at least some embodiments, a deformation step is conducted on the article under effective spin-forming deformation conditions or under effective superplastic deformation conditions. The invention further provides a welded article having suppressed abnormal grain growth, prepared by the process above. Preferably the article is characterized with greater than about 90% reduction in area fraction abnormal grain growth in any friction-stir-welded nugget.

An Operational Fire Hazards Analysis of the C-5

DTIC Science & Technology

1975-02-01

cadmium or lead acid batteries should be installed. (San Antonio A•C) 1. Chine Drain 1) The straight runs of plastic tubing between !MLG wheels should be...JP-5 c. NIL-H-5606, Hydraulic Oil d. NIL-L-7808, Lubricating Oil e. A nonetallic materials such as fabrics, insulation, curtains, plastic panels...14072-1 dat Jan. 8, 1968 "l•ydox (Thermo Formable Plastic ) Self wxtirr-uishin., Test Mcthodc A`S" D-63556T Rhom & 1laas Bul. PL-674B & Itj Sept. 10, 1969

Crystallization, Optical and Chemical Properties of Fluoride Glasses

NASA Technical Reports Server (NTRS)

Doremus, R. H.

1985-01-01

Fluoride glasses have great promise as infrared optical components, especially fibers, because they are transparent to 8 micrometers and higher. In order to optimize properties, different glass compositions are needed. Some are hard to form in a container, and may possibly be formable in a containerless furnace. Understanding of crystallization with and without a container could lead to glasses with optimum properties. Chemical durability (attack by water) can limit or extend the applicability of fluoride glasses. Progress to date is given.

Influence of microscopic strain heterogeneity on the formability of martensitic stainless steel

NASA Astrophysics Data System (ADS)

Bettanini, Alvise Miotti; Delannay, Laurent; Jacques, Pascal J.; Pardoen, Thomas; Badinier, Guillaume; Mithieux, Jean-Denis

2017-10-01

Both finite element modeling and mean field (Mori-Tanaka) modeling are used to predict the strain partitioning in the martensite-ferrite microstructure of an AISI 410 martensitic stainless steel. Numerical predictions reproduce experimental trends according to which macroscopic strength is increased when the dissolution of carbides leads to carbon enrichment of martensite. However, the increased strength contrast of ferrite and martensite favours strain localization and high stress triaxiality in ferrite, which in turn promotes ductile damage development.

Temperature-dependent radiative and non-radiative dynamics of photo-excited carriers in extremely high-density and small InGaN nanodisks fabricated by neutral-beam etching using bio-nano-templates

NASA Astrophysics Data System (ADS)

Chen, Yafeng; Kiba, Takayuki; Takayama, Junichi; Higo, Akio; Tanikawa, Tomoyuki; Chen, Shula; Samukawa, Seiji; Murayama, Akihiro

2018-05-01

Temperature-dependent radiative and non-radiative dynamics of photoexcited carriers were studied in In0.3Ga0.7N nanodisks (NDs) fabricated from quantum wells (QWs) by neutral-beam etching using bio-nano-templates. The NDs had a diameter of 5 nm, a thickness of 2 and 3 nm, and a sheet density of 2 × 1011 cm-2. The radiative decay time, reflecting the displacement between the electron and hole wavefunctions, is about 0.2 ns; this value is almost constant as a function of temperature in the NDs and not dependent on their thickness. We observed non-exponential decay curves of photoluminescence (PL) in the NDs, particularly at temperatures above 150 K. The thermal activation energies of PL quenching in the NDs are revealed to be about 110 meV, corresponding to the barrier heights of the valence bands in the disks. Therefore, hole escape is deemed responsible for the PL quenching, while thermal activation energies of 12 meV due to the trapping of carriers by defects were dominant in the mother QWs. The above-mentioned non-exponential PL decay curves can be attributed to variations in the rate of hole escape in the NDs because of fluctuations in the valence-band barrier height, which, in turn, is possibly due to compositional fluctuations in the QWs. We found that non-radiative trapping, characteristic of the original QW, also exists in about 1% of the NDs in a form that is not masked by other newly formable defects. Therefore, we suggest that additional defect formation is not significant during our ND fabrication process.

Tailorable Burning Behavior of Ti14 Alloy by Controlling Semi-Solid Forging Temperature

PubMed Central

Chen, Yongnan; Yang, Wenqing; Zhan, Haifei; Zhang, Fengying; Huo, Yazhou; Zhao, Yongqing; Song, Xuding; Gu, Yuantong

2016-01-01

Semi-solid processing (SSP) is a popular near-net-shape forming technology for metals, while its application is still limited in titanium alloy mainly due to its low formability. Recent works showed that SSP could effectively enhance the formability and mechanical properties of titanium alloys. The processing parameters such as temperature and forging rate/ratio, are directly correlated with the microstructure, which endow the alloy with different chemical and physical properties. Specifically, as a key structural material for the advanced aero-engine, the burn resistant performance is a crucial requirement for the burn resistant titanium alloy. Thus, this work aims to assess the burning behavior of Ti14, a kind of burn resistant alloy, as forged at different semi-solid forging temperatures. The burning characteristics of the alloy are analyzed by a series of burning tests with different burning durations, velocities, and microstructures of burned sample. The results showed that the burning process is highly dependent on the forging temperature, due to the fact that higher temperatures would result in more Ti2Cu precipitate within grain and along grain boundaries. Such a microstructure hinders the transport of oxygen in the stable burning stage through the formation of a kind of oxygen isolation Cu-enriched layer under the burn product zone. This work suggests that the burning resistance of the alloy can be effectively tuned by controlling the temperature during the semi-solid forging process. PMID:28773820

Damage Evolution in Complex-Phase and Dual-Phase Steels during Edge Stretching.

PubMed

Pathak, Nikky; Butcher, Cliff; Worswick, Michael James; Bellhouse, Erika; Gao, Jeff

2017-03-27

The role of microstructural damage in controlling the edge stretchability of Complex-Phase (CP) and Dual-Phase (DP) steels was evaluated using hole tension experiments. The experiments considered a tensile specimen with a hole at the center of specimen that is either sheared (sheared edge condition) or drilled and then reamed (reamed edge condition). The damage mechanism and accumulation in the CP and DP steels were systematically characterized by interrupting the hole tension tests at different strain levels using scanning electron microscope (SEM) analysis and optical microscopy. Martensite cracking and decohesion of ferrite-martensite interfaces are the dominant nucleation mechanisms in the DP780. The primary source of void nucleation in the CP800 is nucleation at TiN particles, with secondary void formation at martensite/bainite interfaces near the failure strain. The rate of damage evolution is considerably higher for the sheared edge in contrast with the reamed edge since the shearing process alters the microstructure in the shear affected zone (SAZ) by introducing work-hardening and initial damage behind the sheared edge. The CP microstructures were shown to be less prone to shear-induced damage than the DP materials resulting in much higher sheared edge formability. Microstructural damage in the CP and DP steels was characterized to understand the interaction between microstructure, damage evolution and edge formability during edge stretching. An analytical model for void evolution and coalescence was developed and applied to predict the damage rate in these rather diverse microstructures.

Numerical and Experimental Study on Manufacture of a Novel High-Capacity Engine Oil Pan Subjected to Hydro-Mechanical Deep Drawing

NASA Astrophysics Data System (ADS)

Chen, D. Y.; Xu, Y.; Zhang, S. H.; El-Aty, A. Abd; Ma, Y.

2017-09-01

The oil pan is equipped at the bottom of engine crankcase of the automobile to prevent impurity and collect the lubrication oil from the surfaces of the engine which is helpful for heat dissipation and oxidation prevention. The present study aims at manufacturing a novel high-capacity engine oil pan, which is considered as a complex shaped component with features of thin wall, large size and asymmetric deep cavity through both numerical and experimental methods. The result indicated that it is difficult to form the current part through the common deep drawing process. Accordingly, the hydro-mechanical deep drawing technology was conducted, which consisted of two steps, previous local drawing and the final integral deep drawing with hydraulic pressure. The finite element analysis (FEA) was carried out to investigate the influence of initial blank dimension and the key process parameters such as loading path, draw-bead force and fillet radius on the formability of the sheet blank. Compared with the common deep drawing, the limit drawing ratio by hydro-mechanical deep drawing can be increased from 2.34 to 2.77, while the reduction in blank wall thickness can be controlled in the range of 28%. The formability is greatly improved without any defects such as crack and wrinkle by means of parameters optimisation. The results gained from simulation keep a reasonable agreement with that obtained from experiment trials.

Numerical investigation of tube hyroforming of TWT using Corner Fill Test

NASA Astrophysics Data System (ADS)

Zribi, Temim; Khalfallah, Ali

2018-05-01

Tube hydroforming presents a very good alternative to conventional forming processes for obtaining good quality mechanical parts used in several industrial fields, such as the automotive and aerospace sectors. Research in the field of tube hydroforming is aimed at improving the formability, stiffness and weight reduction of manufactured parts using this process. In recent years, a new method of hydroforming appears; it consists of deforming parts made from welded tubes and having different thicknesses. This technique which contributes to the weight reduction of the hydroformed tubes is a good alternative to the conventional tube hydroforming. This technique makes it possible to build rigid and light structures with a reduced cost. However, it is possible to improve the weight reduction by using dissimilar tailor welded tubes (TWT). This paper is a first attempt to analyze by numerical simulation the behavior of TWT hydroformed in square cross section dies, commonly called (Corner Fill Test). Considered tubes are composed of two materials assembled by butt welding. The present analysis will focus on the effect of loading paths on the formability of the structure by determining the change in thickness in several sections of the part. A comparison between the results obtained by hydroforming the butt joint of tubes made of dissimilar materials and those obtained using single-material tube is achieved. Numerical calculations show that the bi-material welded tube has better thinning resistance and a more even thickness distribution in the circumferential directions when compared to the single-material tube.

Massively Parallel Processing for Fast and Accurate Stamping Simulations

NASA Astrophysics Data System (ADS)

Gress, Jeffrey J.; Xu, Siguang; Joshi, Ramesh; Wang, Chuan-tao; Paul, Sabu

2005-08-01

The competitive automotive market drives automotive manufacturers to speed up the vehicle development cycles and reduce the lead-time. Fast tooling development is one of the key areas to support fast and short vehicle development programs (VDP). In the past ten years, the stamping simulation has become the most effective validation tool in predicting and resolving all potential formability and quality problems before the dies are physically made. The stamping simulation and formability analysis has become an critical business segment in GM math-based die engineering process. As the simulation becomes as one of the major production tools in engineering factory, the simulation speed and accuracy are the two of the most important measures for stamping simulation technology. The speed and time-in-system of forming analysis becomes an even more critical to support the fast VDP and tooling readiness. Since 1997, General Motors Die Center has been working jointly with our software vendor to develop and implement a parallel version of simulation software for mass production analysis applications. By 2001, this technology was matured in the form of distributed memory processing (DMP) of draw die simulations in a networked distributed memory computing environment. In 2004, this technology was refined to massively parallel processing (MPP) and extended to line die forming analysis (draw, trim, flange, and associated spring-back) running on a dedicated computing environment. The evolution of this technology and the insight gained through the implementation of DM0P/MPP technology as well as performance benchmarks are discussed in this publication.

Damage Evolution in Complex-Phase and Dual-Phase Steels during Edge Stretching

PubMed Central

Pathak, Nikky; Butcher, Cliff; Worswick, Michael James; Bellhouse, Erika; Gao, Jeff

2017-01-01

The role of microstructural damage in controlling the edge stretchability of Complex-Phase (CP) and Dual-Phase (DP) steels was evaluated using hole tension experiments. The experiments considered a tensile specimen with a hole at the center of specimen that is either sheared (sheared edge condition) or drilled and then reamed (reamed edge condition). The damage mechanism and accumulation in the CP and DP steels were systematically characterized by interrupting the hole tension tests at different strain levels using scanning electron microscope (SEM) analysis and optical microscopy. Martensite cracking and decohesion of ferrite-martensite interfaces are the dominant nucleation mechanisms in the DP780. The primary source of void nucleation in the CP800 is nucleation at TiN particles, with secondary void formation at martensite/bainite interfaces near the failure strain. The rate of damage evolution is considerably higher for the sheared edge in contrast with the reamed edge since the shearing process alters the microstructure in the shear affected zone (SAZ) by introducing work-hardening and initial damage behind the sheared edge. The CP microstructures were shown to be less prone to shear-induced damage than the DP materials resulting in much higher sheared edge formability. Microstructural damage in the CP and DP steels was characterized to understand the interaction between microstructure, damage evolution and edge formability during edge stretching. An analytical model for void evolution and coalescence was developed and applied to predict the damage rate in these rather diverse microstructures. PMID:28772707

Formation of Gradient Structures in the Zone of Joining a Deformable Nickel Alloy and a Single-Crystal Intermetallic Alloy during Thermodiffusion Pressure Welding and Subsequent Heat Treatment

NASA Astrophysics Data System (ADS)

Povarova, K. B.; Valitov, V. A.; Drozdov, A. A.; Bazyleva, O. A.; Galieva, E. V.; Arginbaeva, E. G.

2018-01-01

The possibility of formation of a high-quality solid-phase joint of an Ni3Al-based single-crystal intermetallic VKNA-25 blade alloy with a high-temperature deformable EP975 disk alloy by pressure welding is studied to create high-performance one-piece blisk unit for the next-generation aviation gas turbine engines and to decrease the unit mass. The influence of the conditions of thermodiffusion pressure welding under the hightemperature superplasticity of the disk alloy and the influence of heat treatment of welded joints on the gradient structures in the welded joint zone and the structure at the periphery of the welded samples are investigated.

Study of the application of superplastically formed and diffusion bonded (SPF/DB) titanium structure to laminar flow control (LFC) wing design

NASA Technical Reports Server (NTRS)

Mcquilkin, F. T.

1979-01-01

Eighteen design concepts for a LFC wing cover, using various SPF/DB approaches, were developed. After evaluation of producibility, compatibility with LFC requirements, structural efficiency and fatigue requirements, three candidates were selected for fabrication of demonstration panels. Included were both sandwich and stiffened semi-sandwich panels with slotted and perforated surfaces. Subsequent to the evaluation of the three demonstration panels, one concept was selected for fabrication of a 0.3 x 1.0 meter (12 x 42 inch) feasibility panel. It was a stiffened, semi-sandwich panel with a slotted surface, designed to meet the requirements of the upper wing cover at the maximum wing bending moment of the baseline configuration.

Glass formability of high T(sub c) Bi-Sr-Ca-Cu-O superconductors

NASA Technical Reports Server (NTRS)

Kaukler, William F.

1992-01-01

A number of compositions of ceramic oxide high T(sub c) superconductors were evaluated for their glass formation ability by means of rapid thermal analysis during quenching, optical and electron microscopy of the quenched samples, and with subsequent DSC measurements. Correlations between experimental measurements and the methodical composition changes identified the formulations of superconductors that can easily form glass. The superconducting material was first formed as a glass, then with subsequent devitrification it was formed into bulk crystalline superconductor by a series of processing methods.

Forming and Bending of Metal Foams

NASA Astrophysics Data System (ADS)

Nebosky, Paul; Tyszka, Daniel; Niebur, Glen; Schmid, Steven

2004-06-01

This study examines the formability of a porous tantalum foam, known as trabecular metal (TM). Used as a bone ingrowth surface on orthopedic implants, TM is desirable due to its combination of high strength, low relative density, and excellent osteoconductive properties. This research aims to develop bend and stretch forming as a cost-effective alternative to net machining and EDM for manufacturing thin parts made of TM. Experimentally, bending about a single axis using a wiping die was studied by observing cracking and measuring springback. It was found that die radius and clearance strongly affect the springback properties of TM, while punch speed, embossings, die radius and clearance all influence cracking. Depending on the various combinations of die radius and clearance, springback factor ranged from .70-.91. To examine the affect of the foam microstructure, bending also was examined numerically using a horizontal hexagonal mesh. As the hexagonal cells were elongated along the sheet length, elastic springback decreased. This can be explained by the earlier onset of plastic hinging occurring at the vertices of the cells. While the numerical results matched the experimental results for the case of zero clearance, differences at higher clearances arose due to an imprecise characterization of the post-yield properties of tantalum. By changing the material properties of the struts, the models can be modified for use with other open-cell metallic foams.

Fundamental studies on a novel die concept for round-point shear-clinching

NASA Astrophysics Data System (ADS)

Hörhold, Réjane; Müller, Martin; Merklein, Marion; Meschut, Gerson

2016-10-01

A newly-developed round-point shear-clinching technology could increase the use of different materials like well formable aluminium and hardly formable ultra-high-strength steels (UHSS). This innovative technology joins in a single-stage process without any pilot-hole, surface pre-treatment or auxiliary joining part. The combination of an inner and outer punch realises an indirect cutting operation of the die-sided material, whereas the punch-sided material remains unharmed. The current die-sided tool set acts as a cutting die and enables a radial extrusion of the punch-sided material after being drawn though the created hole in the UHSS. The die has a fixed die depth. After ejecting the joined components, the slug has to be removed from the top of the spring-loaded anvil. The novel die concept investigated in this paper offers the possibility to push the slug continuously through the die in the joining direction. The removed slugs remain inside the die, so manual removal is unnecessary. The one-parted tool is supposed to be more robust than the multi-parted one that is currently used. This paper represents the task to evaluate the geometry of a useful shear-clinching die concept. To reduce the experimental effort, FEM should assist the development of the most promising approach. To quantify the success, conventional shear-clinching with opening die acts as a reference. The results show the high potential and the raison d'être of shear-clinching technologies as a mechanical joining technology for future multimaterial applications especially for UHSS.

Recent Developments in the Formability of Aluminum Alloys

NASA Astrophysics Data System (ADS)

Banabic, Dorel; Cazacu, Oana; Paraianu, Liana; Jurco, Paul

2005-08-01

The paper presents a few recent contributions brought by the authors in the field of the formability of aluminum alloys. A new concept for calculating Forming Limit Diagrams (FLD) using the finite element method is presented. The article presents a new strategy for calculating both branches of an FLD, using a Hutchinson - Neale model implemented in a finite element code. The simulations have been performed with Abaqus/Standard. The constitutive model has been implemented using a UMAT subroutine. The plastic anisotropy of the sheet metal is described by the Cazacu-Barlat and the BBC2003 yield criteria. The theoretical predictions have been compared with the results given by the classical Hutchinson - Neale method and also with experimental data for different aluminum alloys. The comparison proves the capability of the finite element method to predict the strain localization. A computer program used for interactive calculation and graphical representation of different Yield Loci and Forming Limit Diagrams has also been developed. The program is based on a Hutchinson-Neale model. Different yield criteria (Hill 1948, Barlat-Lian and BBC 2003) are implemented in this model. The program consists in three modules: a graphical interface for input, a module for the identification and visualization of the yield surfaces, and a module for calculating and visualizing the forming limit curves. A useful facility offered by the program is the possibility to perform the sensitivity analysis both for the yield surface and the forming limit curves. The numerical results can be compared with experimental data, using the import/export facilities included in the program.

Texture evolution during thermomechanical processing in rare earth free magnesium alloys

NASA Astrophysics Data System (ADS)

Miller, Victoria Mayne

The use of wrought magnesium alloys is highly desirable for a wide range of applications where low component weight is desirable due to the high specific strength and stiffness the alloys can achieve. However, the implementation of wrought magnesium has been hindered by the limited room temperature formability which typically results from deformation processing. This work identifies opportunities for texture modification during thermomechanical processing of conventional (rare earth free) magnesium alloys via a combination of experimental investigation and polycrystal plasticity simulations. During deformation, it is observed that a homogeneous distribution of coarse intermetallic particles efficiently weakens deformation texture at all strain levels, while a highly inhomogeneous particle distribution is only effective at high strains. The particle deformation effects are complemented by the addition of alkaline earth solute, which modifies the relative deformation mode activity. During recrystallization, grains with basal orientations recrystallize more readily than off-basal grains, despite similar levels of internal misorientation. Dislocation substructure investigations revealed that this is a result of enhanced nucleation in the basal grains due to the dominance of prismatic slip. This dissertation identifies avenues to enhance the potential formability of magnesium alloys during thermomechanical processing by minimizing the evolved texture strength. The following are the identified key aspects of microstructural control: -Maintaining a fine grain size, likely via Zener pinning, to favorably modify deformation mode activity and homogenize deformation. -Developing a coarse, homogeneously distributed population of coarse intermetallic particles to promote a diffuse deformation texture. -Minimizing the activity of prismatic slip to retard the recrystallization of grains with basal orientations, allowing the development of a more diffuse recrystallization texture.

Recent Developments in the Formability of Aluminum Alloys

DOE Office of Scientific and Technical Information (OSTI.GOV)

Banabic, Dorel; Paraianu, Liana; Jurco, Paul

The paper presents a few recent contributions brought by the authors in the field of the formability of aluminum alloys. A new concept for calculating Forming Limit Diagrams (FLD) using the finite element method is presented. The article presents a new strategy for calculating both branches of an FLD, using a Hutchinson - Neale model implemented in a finite element code. The simulations have been performed with Abaqus/Standard. The constitutive model has been implemented using a UMAT subroutine. The plastic anisotropy of the sheet metal is described by the Cazacu-Barlat and the BBC2003 yield criteria. The theoretical predictions have beenmore » compared with the results given by the classical Hutchinson - Neale method and also with experimental data for different aluminum alloys. The comparison proves the capability of the finite element method to predict the strain localization. A computer program used for interactive calculation and graphical representation of different Yield Loci and Forming Limit Diagrams has also been developed. The program is based on a Hutchinson-Neale model. Different yield criteria (Hill 1948, Barlat-Lian and BBC 2003) are implemented in this model. The program consists in three modules: a graphical interface for input, a module for the identification and visualization of the yield surfaces, and a module for calculating and visualizing the forming limit curves. A useful facility offered by the program is the possibility to perform the sensitivity analysis both for the yield surface and the forming limit curves. The numerical results can be compared with experimental data, using the import/export facilities included in the program.« less

Design studies of Laminar Flow Control (LFC) wing concepts using superplastics forming and diffusion bonding (SPF/DB)

NASA Technical Reports Server (NTRS)

Wilson, V. E.

1980-01-01

Alternate concepts and design approaches were developed for suction panels and techniques were defined for integrating these panel designs into a complete LFC 200R wing. The design concepts and approaches were analyzed to assure that they would meet the strength, stability, and internal volume requirements. Cost and weight comparisions of the concepts were also made. Problems of integrating the concepts into a complete aircraft system were addressed. Methods for making splices both chordwise and spanwise, fuel light joints, and internal duct installations were developed. Manufacturing problems such as slot aligment, tapered slot spacing, production methods, and repair techniques were addressed. An assessment of the program was used to developed recommendations for additional research in the development of SPF/DB for LFC structure.

Can grain size sensitive creep lubricate faults during earthquake propagation?

NASA Astrophysics Data System (ADS)

De Paola, N.; Holdsworth, R.; Viti, C.; Collettini, C.; Bullock, R. J.; Faoro, I.

2014-12-01

In the shallow portion of crustal fault zones, fracturing and cataclasis are thought to be the dominant processes during earthquake propagation. In the lower crust/upper mantle, viscous flow is inferred to facilitate aseismic creep along shear zones. Recent studies show that slip zones (SZs), in natural and experimental carbonate seismic faults, are made of nanograins with a polygonal texture, a microstructure consistent with deformation by grain boundary sliding (GBS) mechanisms. Friction experiments performed on calcite fine-grained gouges, at speed v = 1 ms-1, normal stress sn = 18 MPa, displacements d = 0.009-1.46 m, and room temperature and humidity, show a four stage-evolution of the fault strength: SI) attainment of initial value, f = 0.67; SII) increase up to peak value f = 0.82; SIII) sudden decrease to low steady-state value, f = 0.18; and SIV) sudden increase to final value, f = 0.44, during sample deceleration. Samples recovered at the end of each displacement-controlled experiments (Stages I-IV) show the following microstructures evolution of the SZ material, which is: SI) poorly consolidated, and made of fine-grained (1 < D < 5 microns), angular clasts formed by brittle fracturing and cataclasis; SII) cohesive, and made of larger clasts of calcite (D ≈ 1 microns), exhibiting a high density of free dislocations and hosting subgrains (D ≤ 200 nm), dispersed within calcite nanograins. SIII) made of nanograin aggregates exhibiting polygonal grain boundaries, and 120° triple junctions between equiaxial grains. The grains display no preferred elongation, no crystal preferred orientation and low free dislocation densities, possibly due to high temperature (> 900 C) GBS creep deformation. Our microstructural observations suggest that GBS mechanisms can operate in geological materials deformed at high strain rates along frictionally heated seismogenic slip surfaces. The observed microstructures in experimental slip zones are strikingly similar to those predicted by theoretical studies, and to those observed during experiments on metals and fine-grained carbonates deformed at T > 900 °C, where superplastic behaviour due to GBS has been inferred. A regime of frictionally-induced GBS could thus account for the dynamic weakening of carbonate faults during earthquake propagation in nature.

The effect of welding line heat-affected-zone on the formability of tube hydroforming process

NASA Astrophysics Data System (ADS)

ChiuHuang, Cheng-Kai; Hsu, Cheng-En; Lee, Ping-Kun

2016-08-01

Tube hydroforming has been used as a lightweight design approach to reduce CO2 emission for the automotive industry. For the high strength steel tube, the strength and quality of the welding line is very important for a successful tube hydroforming process. This paper aims to investigate the effect of the welding line's strength and the width of the heat-affected zone on the tube thinning during the hydroforming process. The simulation results show that both factors play an important role on the thickness distribution during the tube expansion.

Improvement of mechanical behaviors of a superlight Mg-Li base alloy by duplex phases and fine precipitates

DOE PAGES

Zou, Yun; Zhang, Lehao; Li, Yang; ...

2017-12-06

Limitations of strength and formability are the major obstacles to the industrial application of magnesium alloys. Here, we demonstrate, by producing the duplex phases and fine intermetallic particles in composition-optimized superlight Mg-Li-Al alloys, a unique approach to simultaneously improve the comprehensive mechanical properties (a strength-ductility balance). In conclusion, the phase components and microstructures, including the size, morphology, and distribution of precipitated-intermetallic particles can be optimized by tuning the Li content, which strongly influences the work-hardening behavior and tension-compression yield asymmetry.

Increasing the Robustness of the Sheet Metal Forming Simulation by the Prediction of the Forming Limit Band

NASA Astrophysics Data System (ADS)

Banabic, D.; Vos, M.; Paraianu, L.; Jurco, P.

2007-05-01

The experimental research on the formability of metal sheets has shown that there is a significant dispersion of the limit strains in an area delimited by two curves: a lower curve (LFLC) and an upper one (UFLC). The region between the two curves defines the so-called Forming Limit Band (FLB). So far, this forming band has only been determined experimentally. In this paper the authors suggested a method to predict the Forming Limit Band. The proposed method is illustrated on the AA6111-T43 aluminium alloy.

A comparison of deformation and failure behaviors of AZ31 and E-form Mg alloys under V-bending test

NASA Astrophysics Data System (ADS)

Choi, Shi-Hoon; Singh, Jaiveer; Kim, Min-Seong; Yoon, Jeong-Whan

2016-08-01

Deformation and failure behaviors of magnesium (Mg) alloys (AZ31 and E-form) were investigated using V-bending test. Formability of these Mg alloys was discussed in terms of minimum bending radius. Microtexture evolution in the deformed Mg alloys was examined via electron back-scattered diffraction (EBSD) technique. Two level simulation technique which combined continuum finite element method (FEM) and crystal plasticity FEM successfully simulated the microtexture evolution in Mg alloys during V-bending test. The effect of deformation twinning on the failure in Mg alloys was also examined.

Nonlinear friction model for servo press simulation

NASA Astrophysics Data System (ADS)

Ma, Ninshu; Sugitomo, Nobuhiko; Kyuno, Takunori; Tamura, Shintaro; Naka, Tetsuo

2013-12-01

The friction coefficient was measured under an idealized condition for a pulse servo motion. The measured friction coefficient and its changing with both sliding distance and a pulse motion showed that the friction resistance can be reduced due to the re-lubrication during unloading process of the pulse servo motion. Based on the measured friction coefficient and its changes with sliding distance and re-lubrication of oil, a nonlinear friction model was developed. Using the newly developed the nonlinear friction model, a deep draw simulation was performed and the formability was evaluated. The results were compared with experimental ones and the effectiveness was verified.

Surface modification of titanium and titanium alloys by ion implantation.

PubMed

Rautray, Tapash R; Narayanan, R; Kwon, Tae-Yub; Kim, Kyo-Han

2010-05-01

Titanium and titanium alloys are widely used in biomedical devices and components, especially as hard tissue replacements as well as in cardiac and cardiovascular applications, because of their desirable properties, such as relatively low modulus, good fatigue strength, formability, machinability, corrosion resistance, and biocompatibility. However, titanium and its alloys cannot meet all of the clinical requirements. Therefore, to improve the biological, chemical, and mechanical properties, surface modification is often performed. In view of this, the current review casts new light on surface modification of titanium and titanium alloys by ion beam implantation. (c) 2010 Wiley Periodicals, Inc.

Grain dynamics and plastic properties of highly refined materials

NASA Astrophysics Data System (ADS)

Lagos, Miguel; Retamal, César

2010-12-01

It has been shown that a grain boundary may undergo two competing classes of elastic instability when the in-plane shear stress exceeds the proper critical values. It may buckle acquiring a sinusoidal shape or may develop a periodic series of fissures, separating bands with a sigmoidal profile. The two instabilities lead to grain sliding, but the corresponding expressions relating the relative velocity between adjacent grains with stress do differ. The plastic properties for small strains were calculated for the two force laws, which we called force models A and B. A comparison of the theoretical results with published experimental data shows that model A, while giving predictions within the experimental uncertainties for a series of superplastic aluminium and titanium alloys, fails for Avesta 2304 steel. However, excellent results are obtained when model B is applied for this steel.

Adsorption as a method of doping 3-mol%-yttria-stabilized zirconia powder with copper oxides

DOE Office of Scientific and Technical Information (OSTI.GOV)

Seidensticker, J.R.; Mayo, M.J.; Osseo-Asare, K.

The adsorption behavior of Cu[sup 2+] on 3-mol%-yttria-stabilized tetragonal zirconia polycrystalline (3Y-TZP) powder was studied. There is a window of pH values (10 < pH < 11) where adsorption may be used as a method of doping 3Y-TZP with Cu[sup 2+]. The maximum mole percent of the CuO additions is determined by the specific surface area of the 3Y-TZP powder; a powder with a specific surface area of 16.1 m[sup 2]/g is limited to about 1 mol% CuO. Compacts made from powders doped with CuO using this method exhibited an enhancement in superplasticity comparable to that observed in other studiesmore » using samples doped with CuO by attrition milling.« less

Noise and economic characteristics of an advanced blended supersonic transport concept

NASA Technical Reports Server (NTRS)

Molloy, J. K.; Grantham, W. D.; Neubauer, M. J., Jr.

1982-01-01

Noise and economic characteristics were obtained for an advanced supersonic transport concept that utilized wing body blending, a double bypass variable cycle engine, superplastically formed and diffusion bonded titanium in both the primary and secondary structures, and an alternative interior arrangement that provides increased seating capacity. The configuration has a cruise Mach number of 2.62, provisions for 290 passengers, a mission range of 8.19 Mm (4423 n.mi.), and an average operating cruise lift drag ratio of 9.23. Advanced operating procedures, which have the potential to reduce airport community noise, were explored by using a simulator. Traded jet noise levels of 105.7 and 103.4 EPNdB were obtained by using standard and advanced takeoff operational procedures, respectively. A new method for predicting lateral attenuation was utilized in obtaining these jet noise levels.

Possibilities for specific utilization of material properties for an optimal part design

NASA Astrophysics Data System (ADS)

Beier, T.; Gerlach, J.; Roettger, R.; Kuhn, P.

2017-09-01

High-strength, cold-formable steels offer great potential for meeting cost and safety requirements in the automotive industry. In view of strengths of up to 1200 MPa now attainable, certain aspects need to be analysed and evaluated in advance in the development process using these materials. In addition to early assessment of crash properties, it is also highly important to adapt the forming process to match the material potential. The steel making companies have widened their portfolios of cold-rolled dual-phase steels well beyond the conventional high-strength steels. There are added new grades which offer a customized selection of high energy absorption, deformation resistance or enhanced cold-forming properties. In this article the necessary components for material modelling for finite element simulation are discussed. Additionally the required tests for material model calibration are presented and the potentials of the thyssenkrupp Steel material data base are introduced. Besides classical tensile tests at different angles to rolling direction and the forming limit curve, the hydraulic bulge test is now available for a wide range of modern steel grades. Using the conventional DP-K®60/98 and the DP-K®700Y980T with higher yield strength the method for calibrating yield locus, hardening and formability is given. With reference to the examples of an A-pillar reinforcement and different crash tests the procedure is shown how the customer can evaluate an optimal steel grade for specific requirements. Although the investigated materials have different yield strengths, no large differences in the forming process between the two steel grades can be found. However some advantages of the high-yield grade can be detected in crash performance depending on the specific boundary and loading conditions.

Formability of dual-phase steels in deep drawing of rectangular parts: Influence of blank thickness and die radius

NASA Astrophysics Data System (ADS)

López, Ana María Camacho; Regueras, José María Gutiérrez

2017-10-01

The new goals of automotive industry related with environment concerns, the reduction of fuel emissions and the security requirements have driven up to new designs which main objective is reducing weight. It can be achieved through new materials such as nano-structured materials, fibre-reinforced composites or steels with higher strength, among others. Into the last group, the Advance High Strength Steels (AHSS) and particularly, dual-phase steels are in a predominant situation. However, despite of their special characteristics, they present issues related to their manufacturability such as springback, splits and cracks, among others. This work is focused on the deep drawing processof rectangular shapes, a very usual forming operation that allows manufacturing several automotive parts like oil pans, cases, etc. Two of the main parameters in this process which affect directly to the characteristics of final product are blank thickness (t) and die radius (Rd). Influence of t and Rd on the formability of dual-phase steels has been analysed considering values typically used in industrial manufacturing for a wide range of dual-phase steels using finite element modelling and simulation; concretely, the influence of these parameters in the percentage of thickness reduction pt(%), a quite important value for manufactured parts by deep drawing operations, which affects to its integrity and its service behaviour. Modified Morh Coulomb criteria (MMC) has been used in order to obtain Fracture Forming Limit Diagrams (FFLD) which take into account an important failure mode in dual-phase steels: shear fracture. Finally, a relation between thickness reduction percentage and studied parameters has been established fordual-phase steels, obtaining a collection of equations based on Design of Experiments (D.O.E) technique, which can be useful in order to predict approximate results.

Formability of paperboard during deep-drawing with local steam application

NASA Astrophysics Data System (ADS)

Franke, Wilken; Stein, Philipp; Dörsam, Sven; Groche, Peter

2018-05-01

The use of paperboard can significantly improve the environmental compatibility of everyday products such as packages. Nevertheless, most packages are currently made of plastics, since the three-dimensional shaping of paperboard is possible only to a limited extent. In order to increase the forming possibilities, deep drawing of cardboard has been intensively investigated for more than a decade. An improvement with regard to increased forming limits has been achieved by heating of the tool parts, which leads to a softening of paperboard constituents such as lignin. A further approach is the moistening of the samples, whereby the hydrogen bonds between the fibers are weakened and as a result an increase of the formability. It is expected that a combination of both parameter approaches will result in a significant increase in the forming capacity and in the shape accuracy. For this reason, a new tool concept is introduced within the scope of this work which makes it possible to moisten samples during the deep drawing process by means of steam supply. The conducted investigations show that spring-back in the preferred fiber direction can be reduced by 38 %. Orthogonal to the preferred fiber direction a reduction of spring back of up to 79 % is determined, which corresponds to a perfect shape. Moreover, it was determined that the steam duration and the initial moisture content have an influence on the final shape. In addition to the increased dimensional accuracy, an optimized wrinkle compression compared to conventional deep drawing is found. According to the results, it can be summarized that a steam application in the deep drawing of paperboard significantly improves the part quality.

In situ electron microscopy studies of electromechanical behavior in metals at the nanoscale using a novel microdevice-based system

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kang, Wonmo, E-mail: wonmo.kang.ctr.ks@nrl.navy.mil; Beniam, Iyoel; Qidwai, Siddiq M.

Electrically assisted deformation (EAD) is an emerging technique to enhance formability of metals by applying an electric current through them. Despite its increasing importance in manufacturing applications, there is still an unresolved debate on the nature of the fundamental deformation mechanisms underlying EAD, mainly between electroplasticity (non-thermal effects) and resistive heating (thermal effects). This status is due to two critical challenges: (1) a lack of experimental techniques to directly observe fundamental mechanisms of material deformation during EAD, and (2) intrinsic coupling between electric current and Joule heating giving rise to unwanted thermally activated mechanisms. To overcome these challenges, we havemore » developed a microdevice-based electromechanical testing system (MEMTS) to characterize nanoscale metal specimens in transmission electron microscopy (TEM). Our studies reveal that MEMTS eliminates the effect of Joule heating on material deformation, a critical advantage over macroscopic experiments, owing to its unique scale. For example, a negligible change in temperature (<0.02 °C) is predicted at ∼3500 A/mm{sup 2}. Utilizing the attractive features of MEMTS, we have directly investigated potential electron-dislocation interactions in single crystal copper (SCC) specimens that are simultaneously subjected to uniaxial loading and electric current density up to 5000 A/mm{sup 2}. Our in situ TEM studies indicate that for SCC, electroplasticity does not play a key role as no differences in dislocation activities, such as depinning and movement, are observed.« less

Role of atomic bonding for compound and glass formation in Ni-Si, Pd-Si, and Ni-B systems

NASA Astrophysics Data System (ADS)

Tanaka, K.; Saito, T.; Suzuki, K.; Hasegawa, R.

1985-11-01

Valence electronic structures of crystalline compounds and glassy alloys of Ni silicides, Pd silicides, and Ni borides are studied by soft-x-ray spectroscopy over wide ranges of Si and B concentrations. The samples prepared include bulk compounds, glassy ribbons, and amorphous sputtered films. Silicon Kβ emissions of Ni and Pd silicides generally consist of a prominent peak fixed at ~=4.5 and ~=5.8 eV below the Fermi level EF, respectively, with a shoulder near EF which grows and shifts toward lower energy with increasing Si concentration. The former is identified as due to Si p-like states forming Si 3p-Ni 3d or Si 3p-Pd 4d bonding states while the latter as due to the corresponding antibonding states. Ni L3 and Pd L3 emissions of these silicides indicate that Ni 3d and Pd 4d states lie between the above two states. These local electronic configurations are consistent with partial-density-of-states (PDOS) calculations performed by Bisi and Calandra. Similar electronic configurations are suggested for Ni borides from B Kα and Ni L3 emissions. Differences of emission spectra between compounds and glasses of similar compositions are rather small, but some enhancement of the contribution of antibonding states to the PDOS near EF is suggested for certain glasses over that of the corresponding compounds. These features are discussed in connection with the compound stability and glass formability.

A Novel Method for In Situ Electromechanical Characterization of Nanoscale Specimens

PubMed Central

Reid, Russell C.; Piqué, Alberto; Kang, Wonmo

2017-01-01

Electrically assisted deformation (EAD) is increasingly being used to improve the formability of metals during processes such as sheet metal rolling and forging. Adoption of this technique is proceeding despite disagreement concerning the underlying mechanism responsible for EAD. The experimental procedure described herein enables a more explicit study compared to previous EAD research by removing thermal effects, which are responsible for disagreement in interpreting previous EAD results. Furthermore, as the procedure described here enables EAD observation in situ and in real time in a transmission electron microscope (TEM), it is superior to existing post-mortem methods that observe EAD effects post-test. Test samples consist of a single crystal copper (SCC) foil having a free-standing tensile test section of nanoscale thickness, fabricated using a combination of laser and ion beam milling. The SCC is mounted to an etched silicon base that provides mechanical support and electrical isolation while serving as a heat sink. Using this geometry, even at high current density (~3,500 A/mm2), the test section experiences a negligible temperature increase (<0.02 °C), thus eliminating Joule heating effects. Monitoring material deformation and identifying the corresponding changes to microstructures, e.g. dislocations, are accomplished by acquiring and analyzing a series of TEM images. Our sample preparation and in situ experiment procedures are robust and versatile as they can be readily utilized to test materials with different microstructures, e.g., single and polycrystalline copper. PMID:28605394

High strength, low carbon, dual phase steel rods and wires and process for making same

DOEpatents

Thomas, Gareth; Nakagawa, Alvin H.

1986-01-01

A high strength, high ductility, low carbon, dual phase steel wire, bar or rod and process for making the same is provided. The steel wire, bar or rod is produced by cold drawing to the desired diameter in a single multipass operation a low carbon steel composition characterized by a duplex microstructure consisting essentially of a strong second phase dispersed in a soft ferrite matrix with a microstructure and morphology having sufficient cold formability to allow reductions in cross-sectional area of up to about 99.9%. Tensile strengths of at least 120 ksi to over 400 ksi may be obtained.

Effect of Hydraulic Pressure on Warm Hydro Mechanical Deep Drawing of Magnesium Alloy Sheet

NASA Astrophysics Data System (ADS)

Liu, Wei; Wu, Linzhi; Yuan, Shijian

The uniaxial tensile test and hydraulic bulging test of AZ31 magnesium alloy sheets were applied to study the influence of temperature on the material properties and obtain the forming limit curves at different temperatures. Numerical simulations of warm hydro mechanical deep drawing were carried out to investigate the effect of hydraulic pressure on the formability of a cylindrical cup, and the simplified hydraulic pressure profiles were used to simulate the loading procedure of hydraulic pressure. The optimal hydraulic pressure at different temperatures were given and verified by experimental studies at temperature 100°C and 170V.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Yamanaka, Masashi; Dohmae, Takeshi; Hocker, Andy

We are developing the manufacturing method for superconducting radio frequency (SRF) cavities by using a hydroforming instead of using conventional electron beam welding. We expect higher reliability and reduced cost with hydroforming. For successful hydroforming, high-purity seamless niobium tubes with good formability as well as advancing the hydroforming technique are necessary. Using a seamless niobium tube from ATI Wah Chang, we were able to successfully hydroform a 1.3 GHz three-cell TESLA-like cavity and obtained an Eacc of 32 MV/m. A barrel polishing process was omitted after the hydroforming. The vertical test was carried out with very rough inside surface. Wemore » got amazing and interesting result.« less

THE BALLISTICS OF A RIBBON COMPOSITE

DOE Office of Scientific and Technical Information (OSTI.GOV)

Larcombe, J.; Morley, M.; Earp, S.

2009-12-28

The impact behaviour of composites is of great importance in the field of aerospace and vehicle protection. The combination of formability, lightness and strength make composite systems attractive compared to equivalent monolithic systems. However, their use as optical components has been hampered by their lack of transparency. Transparency is strongly affected by refractive index differences in the materials that form the composite. In this study a number of ribbon-based composites were produced. The impact velocity, sample deformation during the impact process and residual impactor velocity were measured. This allowed comparison between the materials ballistic efficiency. The materials are then comparedmore » to other transparent systems.« less

Flexible polymeric rib waveguide with self-align couplers system

PubMed Central

Huang, Cheng-Sheng; Wang, Wei-Chih

2011-01-01

The authors report a polymeric based rib waveguide with U shape self-align fiber couplers system using a simple micromolding process with SU8 as a molding material and polydimethysiloxane as a waveguide material. The material is used for its good optical transparency, low surface tension, biocompatibility, and durability. Furthermore, the material is highly formable. This unique fabrication molding technique provides a means of keeping the material and manufacturing costs to a minimum. The self-align fiber couplers system also proves a fast and simple means of light coupling. The flexible nature of the waveguide material makes this process ideal for a potential wearable optical sensor. PMID:22171151

Optimization of a Tube Hydroforming Process

NASA Astrophysics Data System (ADS)

Abedrabbo, Nader; Zafar, Naeem; Averill, Ron; Pourboghrat, Farhang; Sidhu, Ranny

2004-06-01

An approach is presented to optimize a tube hydroforming process using a Genetic Algorithm (GA) search method. The goal of the study is to maximize formability by identifying the optimal internal hydraulic pressure and feed rate while satisfying the forming limit diagram (FLD). The optimization software HEEDS is used in combination with the nonlinear structural finite element code LS-DYNA to carry out the investigation. In particular, a sub-region of a circular tube blank is formed into a square die. Compared to the best results of a manual optimization procedure, a 55% increase in expansion was achieved when using the pressure and feed profiles identified by the automated optimization procedure.

Comparing Laser Welding Technologies with Friction Stir Welding for Production of Aluminum Tailor-Welded Blanks

DOE Office of Scientific and Technical Information (OSTI.GOV)

Hovanski, Yuri; Carsley, John; Carlson, Blair

2014-01-15

A comparison of welding techniques was performed to determine the most effective method for producing aluminum tailor-welded blanks for high volume automotive applications. Aluminum sheet was joined with an emphasis on post weld formability, surface quality and weld speed. Comparative results from several laser based welding techniques along with friction stir welding are presented. The results of this study demonstrate a quantitative comparison of weld methodologies in preparing tailor-welded aluminum stampings for high volume production in the automotive industry. Evaluation of nearly a dozen welding variations ultimately led to down selecting a single process based on post-weld quality and performance.

Investigation of immiscible systems and potential applications

NASA Technical Reports Server (NTRS)

Markworth, A. J.; Oldfield, W.; Duga, J.; Gelles, S. H.

1975-01-01

The droplet coalescence kinetics at 0 g and 1 g were considered for two systems which contained liquid droplets in a host liquid. One of these (Al-In) typified a system containing a liquid phase miscibility gap and the order (oil-water) a mixture of two essentially insoluble liquids. A number of coalescence mechanisms potentially prominent at low g in this system were analyzed and explanations are presented for the observed unusual stability of the emulsion. Ground base experiments were conducted on the coalescence of In droplets in and Al-In alloy during cooling through the miscibility gap at different cooling rates. These were in qualitative agreement with the computer simulation. Potential applications for systems with liquid phase miscibility gaps were explored. Possibilities included superconductors, electrical contact materials, superplastic materials, catalysts, magnetic materials, and others. The role of space processing in their production was also analyzed.

Maintaining High Strength in Mg-LPSO Alloys with Low Yttrium Content Using Severe Plastic Deformation.

PubMed

Garces, Gerardo; Cabeza, Sandra; Barea, Rafael; Pérez, Pablo; Adeva, Paloma

2018-05-05

Alternative processing routes such as powder metallurgy, the extrusion of recycled chips, or equal channel angular pressing (ECAP) have been considered for effective methods of maintaining the high mechanical strength of Mg-Y-Zn alloys containing long-period stacking ordered structures with respect to the alloy processed by the conventional extrusion of as-cast ingots with the advantage of minimizing the yttrium content. A yield stress similar to that found for extruded Mg 97 Y₂Zn₁ alloy can be attained with only half of the usual yttrium and zinc additions thanks to the grain refinement induced by ECAP processing. The properties of Mg 98.5 Y₁Zn 0.5 subjected to ECAP are maintained up to 200 °C, but superplastic behavior is found above this temperature when the alloy is processed through a powder metallurgy route.

Effects of Hot Rolling on Low-Cycle Fatigue Properties of Zn-22 wt.% Al Alloy at Room Temperature

NASA Astrophysics Data System (ADS)

Dong, X. H.; Cao, Q. D.; Ma, S. J.; Han, S. H.; Tang, W.; Zhang, X. P.

2016-09-01

The effects of the reduction ratio (RR) on the low-cycle fatigue (LCF) properties of the Zn-22 wt.% Al (Zn-22Al) alloy were investigated. Various grain sizes from 0.68 to 1.13 μm were obtained by controlled RRs. Tensile and LCF tests were carried out at room temperature. Superplasticity and cyclic softening were observed. Strength and ductility of the rolled Zn-22Al alloy increased with the RR, owing to the decrease in its grain size. The RR did not affect the cyclic softening behavior of the alloy. The fatigue life of the alloy decreased with increasing strain amplitude, while the fatigue life first decreased and then increased with increasing RR. The longest fatigue life was observed for the alloy rolled at a RR of 60%. A bilinear Coffin-Manson relationship was observed to hold true for this alloy.

Electrocatalysis-induced elasticity modulation in a superionic proton conductor probed by band-excitation atomic force microscopy.

PubMed

Papandrew, A B; Li, Q; Okatan, M B; Jesse, S; Hartnett, C; Kalinin, S V; Vasudevan, R K

2015-12-21

Variable temperature band-excitation atomic force microscopy in conjunction with I-V spectroscopy was used to investigate the crystalline superionic proton conductor CsHSO4 during proton exchange induced by a Pt-coated conductive scanning probe. At a sample temperature of 150 °C and under an applied bias <1 V, reduction currents of up to 1 nA were observed. Simultaneously, we show that the electrochemical reactions are accompanied by a reversible decrease in the elastic modulus of CsHSO4, as seen by a contact resonance shift, and find evidence for superplasticity during scanning. These effects were not observed in the room-temperature phase of CsHSO4 or in the case of catalytically inactive conductive probes, proving the utility of this technique for monitoring electrochemical processes on the nanoscale, as well as the use of local contact stiffness as a sensitive indicator of electrochemical reactions.

Laminar flow control SPF/08 feasibility demonstration

NASA Astrophysics Data System (ADS)

Ecklund, R. C.; Williams, N. R.

1981-10-01

The feasibility of applying superplastic forming/diffusion bonding (SPF/DB) technology to laminar flow control (LFC) system concepts was demonstrated. Procedures were developed to produce smooth, flat titanium panels, using thin -0.016 inch sheets, meeting LFC surface smoothness requirements. Two large panels 28 x 28 inches were fabricated as final demonstration articles. The first was flat on the top and bottom sides demonstrating the capability of the tooling and the forming and diffusion bonding procedures to produce flat, defect free surfaces. The second panel was configurated for LFC porous panel treatment by forming channels with dimpled projections on the top side. The projections were machined away leaving holes extending into the panel. A perforated titanium sheet was adhesively bonded over this surface to complete the LFC demonstration panel. The final surface was considered flat enough to meet LFC requirements for a jet transport aircraft in cruising flight.

Advanced high-temperature alloys: Processing and properties; Proceedings of the Nicholas J. Grant Symposium, MIT, Cambridge, MA, June 16-18, 1985

DOE Office of Scientific and Technical Information (OSTI.GOV)

Allen, S.M.; Pelloux, R.M.; Widmer, R.

1986-01-01

Historical and advanced methods of producing, forming and polishing alloys in billets and net shapes are explored. Attention is given to the deficiencies in arc furnace melts and to the benefits which are accruing from rapid solidification processing, powder metallurgy and superplastic forming. The techniques employed in these methods for processing materials to desired shapes, mainly for aircraft gas turbine engines, are described, along with the microstructures and mechanical properties which are obtained. The state of the art in casting and forming techniques which yield the most favorable properties in intermetallic compound-based alloys, superalloys, glasses and metacrystals are identified. Finally,more » research directions being pursued to obtain higher purity, enhanced temperature, longer lifetime, damage resistant alloys which can be formed to net shapes are discussed.« less

Slip-activated surface creep with room-temperature super-elongation in metallic nanocrystals

DOE Office of Scientific and Technical Information (OSTI.GOV)

Zhong, Li; Sansoz, Frederic; He, Yang

2016-11-28

Atom diffusion assisted by surfaces or interfaces (e.g. Coble creep) has been known to be the origin of large creep rates and superplastic softening in nanosized crystals at low temperature. By contrast, source-limited crystal slip in defect-free nanostructures engenders important strengths, but also premature plastic instability and low ductility. Here, using in-situ transmission electron microscopy, we report a slip-activated surface creep mechanism that suppresses the tendency towards plastic instability without compromising the strength, resulting in ultra-large room-temperature plasticity in face-centered-cubic silver nanocrystals. This phenomenon is shown experimentally and theoretically to prevail over a material-dependent range of diameters where surface dislocationmore » nucleation becomes a stimulus to diffusional creep. This work provides new fundamental insight into coupled diffusive-displacive deformation mechanisms maximizing ductility and strength simultaneously in nanoscale materials.« less

Predicting Hot Deformation of AA5182 Sheet

NASA Astrophysics Data System (ADS)

Lee, John T.; Carpenter, Alexander J.; Jodlowski, Jakub P.; Taleff, Eric M.

Aluminum 5000-series alloy sheet materials exhibit substantial ductilities at hot and warm temperatures, even when grain size is not particularly fine. The relatively high strain-rate sensitivity exhibited by these non-superplastic materials, when deforming under solute-drag creep, is a primary contributor to large tensile ductilities. This active deformation mechanism influences both plastic flow and microstructure evolution across conditions of interest for hot- and warm-forming. Data are presented from uniaxial tensile and biaxial bulge tests of AA5182 sheet material at elevated temperatures. These data are used to construct a material constitutive model for plastic flow, which is applied in finite-element-method (FEM) simulations of plastic deformation under multiaxial stress states. Simulation results are directly compared against experimental data to explore the usefulness of this constitutive model. The effects of temperature and stress state on plastic response and microstructure evolution are discussed.

Weldability of Advanced High Strength Steels using Ytterbium:Yttrium Aluminium Garnet high power laser for Tailor-Welded Blank applications

NASA Astrophysics Data System (ADS)

Sharma, Rajashekhar Shivaram

Use of a high power Yb:YAG laser is investigated for joining advanced high strength steel materials for use in tailor-welded blank (TWB) applications. TWB's are materials of different chemistry, coating or thicknesses that are joined before metal forming and other operations such as trimming, assembly and painting are carried out. TWB is becoming an important design tool in the automotive industry for reducing weight, improving fuel economy and passenger safety, while reducing the overall costs for the customer. Three advanced high strength steels, TRIP780, DP980 and USIBOR, which have many unique properties that are conducive to achieving these objectives, along with mild steel, are used in this work. The objective of this work is to ensure that high quality welds can be obtained using Yb:YAG lasers which are also becoming popular for metal joining operations, since they produce high quality laser beams that suffer minimal distortion when transported via fiber optic cables. Various power levels and speeds for the laser beam were used during the investigation. Argon gas was consistently used for shielding purposes during the welding process. After the samples were welded, metallographic examination of the fusion and heat-affected zones using optical and scanning electron microscopes were carried out to determine the microstructures as well as weld defects. Optical and scanning electron microscopes were also used to examine the top of welds as well as fracture surfaces. Additionally, cross-weld microhardness evaluations, tensile tests using Instron tester, limited fatigue tests as well as formability evaluations using OSU plane strain evaluation were carried out. The examinations included a 2-factor full factorial design of experiments to determine the impact of coatings on the surface roughness on the top of the welds. Tensile strengths of DP980, TRIP780 and mild steel materials as well as DP980 welded to TRIP780 and mild steel in the rolling direction as well as transverse direction were evaluated. Metallographic examinations determined that most of the fusion zone is martensitic with small regions of bainite and ferrite. High microhardness values of the order of 550--600 Hv were noted in most joints, which are attributed to high alloy content of the fusion zone as well as high rates of cooling typical of laser welds. During tensile, fatigue and formability tests, no fractures in the fusion or heat affected zones were observed. Geometric variability evaluations indicated that coatings such as aluminum (in the case of USIBOR) and galvanized zinc (TRIP780) can affect the variability of the weld zone and the surface roughness on the top of the weld. Excessive variability in the form of weld concavity in the weld zones can lead to fractures in the weld region, even though higher hardness can, to some extent, compensate for these surface irregularities. The 2-factor design of experiments further confirmed that coatings adversely affect the surface roughness on the top of the welds. Although thickness differentials alone do not make a significant impact on surface roughness, together with coatings, they can have an adverse effect on roughness. Tensile tests in the direction of rolling as well as in the transverse direction indicate that TRIP780 seems weaker in the direction of rolling when compared to transverse direction while mild steel is stronger in the direction of rolling. Weldability analyses revealed that the typical melting efficiency is on the order of 50--70% for full penetration welding. Formability tests showed that TR/MS joints fractured in a direction parallel to the weld line when tested with the loads perpendicular to the weld line. Tests have also confirmed that weld speed and power have no impact on the outcome of formability results. Overall, this work conclusively proves that high power Yb:YAG lasers can effectively join high strength materials such as DP980, TRIP780, USIBOR, as well as mild steel, for use in tailor-welded blank applications, contributing to lighter, more fuel-efficient and safer vehicles.

Study of The Effect of Draw-bead Geometry on Stretch Flange Formability

NASA Astrophysics Data System (ADS)

Orlov, O. S.; Winkler, S. L.; Worswick, M. J.; Lloyd, D. J.; Finn, M. J.

2004-06-01

A fully instrumented stretch flange press equipped with a back-up punch and draw-beads near the specimen cutout area is simulated. The utilization of different draw-bead geometries is examined numerically to determine the restraining forces, strains and amount of damage generated in stretch flanges during forming. Simulations of the forming process are conducted for 1mm AA5182 sheets with circular cutouts. The damage evolution with the deformed specimens is investigated using the explicit dynamic finite element code, LS-DYNA, with a modified Gurson-based material model. It was found that double draw-beads can provide the same amount of restraining force as single draw-beads, but at reduced levels of damage.

Local heat treatment of high strength steels with zoom-optics and 10kW-diode laser

NASA Astrophysics Data System (ADS)

Baumann, Markus; Krause, Volker; Bergweiler, Georg; Flaischerowitz, Martin; Banik, Janko

2012-03-01

High strength steels enable new solutions for weight optimized car bodies without sacrificing crash safety. However, cold forming of these steels is limited due to the need of high press capacity, increased tool wear, and limitations in possible geometries. One can compensate for these drawbacks by local heat treatment of the blanks. In high-deformation areas the strength of the material is reduced and the plasticity is increased by diode laser irradiation. Local heat treatment with diode laser radiation could also yield key benefits for the applicability of press hardened parts. High strength is not desired all over the part. Joint areas or deformation zones for requested crash properties require locally reduced strength. In the research project "LOKWAB" funded by the German Federal Ministry of Education and Research (BMBF), heat treatment of high strength steels was investigated in cooperation with Audi, BMW, Daimler, ThyssenKrupp, Fraunhofer- ILT, -IWU and others. A diode laser with an output power of 10 kW was set up to achieve acceptable process speed. Furthermore a homogenizing zoom-optics was developed, providing a rectangular focus with homogeneous power density. The spot size in x- and y-direction can be changed independently during operation. With pyrometer controlled laser power the surface temperature is kept constant, thus the laser treated zone can be flexibly adapted to the needs. Deep-drawing experiments show significant improvement in formability. With this technique, parts can be manufactured, which can conventionally only be made of steel with lower strength. Locally reduced strength of press hardened serial parts was demonstrated.

Multi objective genetic algorithm to optimize the local heat treatment of a hardenable aluminum alloy

NASA Astrophysics Data System (ADS)

Piccininni, A.; Palumbo, G.; Franco, A. Lo; Sorgente, D.; Tricarico, L.; Russello, G.

2018-05-01

The continuous research for lightweight components for transport applications to reduce the harmful emissions drives the attention to the light alloys as in the case of Aluminium (Al) alloys, capable to combine low density with high values of the strength-to-weight ratio. Such advantages are partially counterbalanced by the poor formability at room temperature. A viable solution is to adopt a localized heat treatment by laser of the blank before the forming process to obtain a tailored distribution of material properties so that the blank can be formed at room temperature by means of conventional press machines. Such an approach has been extensively investigated for age hardenable alloys, but in the present work the attention is focused on the 5000 series; in particular, the optimization of the deep drawing process of the alloy AA5754 H32 is proposed through a numerical/experimental approach. A preliminary investigation was necessary to correctly tune the laser parameters (focus length, spot dimension) to effectively obtain the annealed state. Optimal process parameters were then obtained coupling a 2D FE model with an optimization platform managed by a multi-objective genetic algorithm. The optimal solution (i.e. able to maximize the LDR) in terms of blankholder force and extent of the annealed region was thus evaluated and validated through experimental trials. A good matching between experimental and numerical results was found. The optimal solution allowed to obtain an LDR of the locally heat treated blank larger than the one of the material either in the wrought condition (H32) either in the annealed condition (H111).

Tribological investigation of novel HDPE-HAp-Al2O3 hybrid biocomposites against steel under dry and simulated body fluid condition.

PubMed

Nath, Shekhar; Bodhak, Subhadip; Basu, Bikramjit

2007-10-01

Among various biocompatible polymers, polyethylene based materials have received wider attention because of its excellent stability in body fluid, inertness, and easy formability. Attempts have been made to improve their physical properties (modulus/strength) to enable them to be used as load bearing hard tissue replacement applications. Among such attempts, high density polyethylene (HDPE)-hydroxyapatite (HAp) composite (HAPEX), has already been developed for total hip replacement (THR) acetabular cup and low load bearing bone tissue replacement. In the present work, alumina has been added as a partial replacement of HAp phase to improve the mechanical and tribological properties of the HAPEX composite. In an attempt to assess the suitability of the developed composite in THR application, the tribological properties against steel counterbody under both in air and simulated body fluid (SBF), have been investigated and efforts have been made to understand the wear mechanisms. The fretting wear study indicates the possibility of achieving extremely low COF (Coefficient of Friction approximately 0.09) as well as higher wear resistance (order of 10(-6) mm(3)/N m) with the newly developed composites in SBF. A low wear depth of approximately 4.6-5.3 microm is recorded, irrespective of fretting environment. The implication of the work is that optimal and combined addition of bioactive and bioinert ceramic filler to HDPE can provide a good opportunity to obtain hybrid biocomposites with better combination of physical properties (modulus, hardness) as well as low friction and high wear resistance.

Contraction Twinning Dominated Tensile Deformation and Subsequent Fracture in Extruded Mg-1Mn (Wt Pct) at Ambient Temperature

NASA Astrophysics Data System (ADS)

Chakkedath, A.; Maiti, T.; Bohlen, J.; Yi, S.; Letzig, D.; Eisenlohr, P.; Boehlert, C. J.

2018-06-01

Due to their excellent strength-to-weight ratio, Mg alloys are attractive for applications where weight savings are critical. However, the limited cold formability of wrought Mg alloys severely restricts their widespread usage. In order to study the role that deformation twinning might play in limiting the elongation-to-failure ({ɛ} _{ {f}}), in-situ tensile tests along the extrusion axis of Mg-1Mn (wt pct) were performed at 323 K, 423 K, and 523 K. The alloy exhibited a strong basal texture such that most of the grains experienced compression along their < {c}> -axis during deformation. At 323 K, fracture occurred at about 10 pct strain. Although basal, prismatic, and pyramidal < {c+a}> slip activity was observed along with extension twinning, contraction twinning significantly influenced the deformation, and such twins evolved into {10{\\bar{1}}1}-{10{\\bar{1}}2} double twins. Crystal plasticity simulation showed localized shear deformation within the contraction twins and double twins due to the enhanced activity of basal slip in the reoriented twin volume. Due to this, the twin-matrix interface was identified to be a potential crack initiation site. Thus, contraction twins were considered to have led to the failure of the material at a relatively low strain, suggesting that this deformation mode is detrimental to the cold formability of Mg and its alloys. With increasing temperature, there was a significant decrease in the activity of contraction twinning as well as extension twinning, along with a decrease in the tensile strength and an increase in the {ɛ} _{ {f}} value. A combination of basal, prismatic, and pyramidal < {c+a}> slips accounted for a large percentage of the observed deformation activity at 423 K and 523 K. The lack of contraction twinning was explained by the expected decrease in the critical resolved shear stress values for pyramidal < {c+a}> slip, and the improved {ɛ} _{ {f}} values at elevated temperatures were attributed to the vanishing activity of contraction twinning.

New Modelling of Localized Necking in Sheet Metal Stretching

NASA Astrophysics Data System (ADS)

Bressan, José Divo

2011-01-01

Present work examines a new mathematical model to predict the onset of localized necking in the industrial processes of sheet metal forming such as biaxial stretching. Sheet metal formability is usually assessed experimentally by testing such as the Nakajima test to obtain the Forming Limit Curve, FLC, which is an essential material parameter necessary to numerical simulations by FEM. The Forming Limit Diagram or "Forming Principal Strain Map" shows the experimental FLC which is the plot of principal true strains in the sheet metal surface, ɛ1 and ɛ2, occurring at critical points obtained in laboratory formability tests or in the fabrication process. Two types of undesirable rupture mechanisms can occur in sheet metal forming products: localized necking and shear induced fracture. Therefore, two kinds of limit strain curves can be plotted: the local necking limit curve FLC-N and the shear fracture limit curve FLC-S. Localized necking is theoretically anticipated to initiate at a thickness defect ƒin = hib/hia inside the grooved sheet thickness hia, but only at the instability point of maximum load. The inception of grooving on the sheet surface evolves from instability point to localized necking and final rupture, during further sheet metal straining. Work hardening law is defined for a strain and strain rate material by the effective stress σ¯ = σo(1+βɛ¯)n???ɛM. The average experimental hardening law curve for tensile tests at 0°, 45° and 90°, assuming isotropic plasticity, was used to analyze the plasticity behavior during the biaxial stretching of sheet metals. Theoretical predicted curves of local necking limits are plotted in the positive quadrant of FPSM for different defect values ƒin and plasticity parameters. Limit strains are obtained from a software developed by the author. Some experimental results of forming limit curve obtained from experiments for IF steel sheets are compared with the theoretical predicted curves: the correlation is good.

Contraction Twinning Dominated Tensile Deformation and Subsequent Fracture in Extruded Mg-1Mn (Wt Pct) at Ambient Temperature

NASA Astrophysics Data System (ADS)

Chakkedath, A.; Maiti, T.; Bohlen, J.; Yi, S.; Letzig, D.; Eisenlohr, P.; Boehlert, C. J.

2018-03-01

Due to their excellent strength-to-weight ratio, Mg alloys are attractive for applications where weight savings are critical. However, the limited cold formability of wrought Mg alloys severely restricts their widespread usage. In order to study the role that deformation twinning might play in limiting the elongation-to-failure ({ɛ} f ), in-situ tensile tests along the extrusion axis of Mg-1Mn (wt pct) were performed at 323 K, 423 K, and 523 K. The alloy exhibited a strong basal texture such that most of the grains experienced compression along their < {c}> -axis during deformation. At 323 K, fracture occurred at about 10 pct strain. Although basal, prismatic, and pyramidal < {c+a}> slip activity was observed along with extension twinning, contraction twinning significantly influenced the deformation, and such twins evolved into {10{\\bar{1}} 1}-{10{\\bar{1}} 2} double twins. Crystal plasticity simulation showed localized shear deformation within the contraction twins and double twins due to the enhanced activity of basal slip in the reoriented twin volume. Due to this, the twin-matrix interface was identified to be a potential crack initiation site. Thus, contraction twins were considered to have led to the failure of the material at a relatively low strain, suggesting that this deformation mode is detrimental to the cold formability of Mg and its alloys. With increasing temperature, there was a significant decrease in the activity of contraction twinning as well as extension twinning, along with a decrease in the tensile strength and an increase in the {ɛ} f value. A combination of basal, prismatic, and pyramidal < {c+a}> slips accounted for a large percentage of the observed deformation activity at 423 K and 523 K. The lack of contraction twinning was explained by the expected decrease in the critical resolved shear stress values for pyramidal < {c+a}> slip, and the improved {ɛ} f values at elevated temperatures were attributed to the vanishing activity of contraction twinning.

A meta-model based approach for rapid formability estimation of continuous fibre reinforced components

NASA Astrophysics Data System (ADS)

Zimmerling, Clemens; Dörr, Dominik; Henning, Frank; Kärger, Luise

2018-05-01

Due to their high mechanical performance, continuous fibre reinforced plastics (CoFRP) become increasingly important for load bearing structures. In many cases, manufacturing CoFRPs comprises a forming process of textiles. To predict and optimise the forming behaviour of a component, numerical simulations are applied. However, for maximum part quality, both the geometry and the process parameters must match in mutual regard, which in turn requires numerous numerically expensive optimisation iterations. In both textile and metal forming, a lot of research has focused on determining optimum process parameters, whilst regarding the geometry as invariable. In this work, a meta-model based approach on component level is proposed, that provides a rapid estimation of the formability for variable geometries based on pre-sampled, physics-based draping data. Initially, a geometry recognition algorithm scans the geometry and extracts a set of doubly-curved regions with relevant geometry parameters. If the relevant parameter space is not part of an underlying data base, additional samples via Finite-Element draping simulations are drawn according to a suitable design-table for computer experiments. Time saving parallel runs of the physical simulations accelerate the data acquisition. Ultimately, a Gaussian Regression meta-model is built from the data base. The method is demonstrated on a box-shaped generic structure. The predicted results are in good agreement with physics-based draping simulations. Since evaluations of the established meta-model are numerically inexpensive, any further design exploration (e.g. robustness analysis or design optimisation) can be performed in short time. It is expected that the proposed method also offers great potential for future applications along virtual process chains: For each process step along the chain, a meta-model can be set-up to predict the impact of design variations on manufacturability and part performance. Thus, the method is considered to facilitate a lean and economic part and process design under consideration of manufacturing effects.

Can grain size sensitive flow lubricate faults during the initial stages of earthquake propagation?

NASA Astrophysics Data System (ADS)

De Paola, Nicola; Holdsworth, Robert E.; Viti, Cecilia; Collettini, Cristiano; Bullock, Rachael

2015-12-01

Recent friction experiments carried out under upper crustal P-T conditions have shown that microstructures typical of high temperature creep develop in the slip zone of experimental faults. These mechanisms are more commonly thought to control aseismic viscous flow and shear zone strength in the lower crust/upper mantle. In this study, displacement-controlled experiments have been performed on carbonate gouges at seismic slip rates (1 m s-1), to investigate whether they may also control the frictional strength of seismic faults at the higher strain rates attained in the brittle crust. At relatively low displacements (<1 cm) and temperatures (≤100 °C), brittle fracturing and cataclasis produce shear localisation and grain size reduction in a thin slip zone (150 μm). With increasing displacement (up to 15 cm) and temperatures (T up to 600 °C), due to frictional heating, intracrystalline plasticity mechanisms start to accommodate intragranular strain in the slip zone, and play a key role in producing nanoscale subgrains (≤100 nm). With further displacement and temperature rise, the onset of weakening coincides with the formation in the slip zone of equiaxial, nanograin aggregates exhibiting polygonal grain boundaries, no shape or crystal preferred orientation and low dislocation densities, possibly due to high temperature (>900 °C) grain boundary sliding (GBS) deformation mechanisms. The observed micro-textures are strikingly similar to those predicted by theoretical studies, and those observed during experiments on metals and fine-grained carbonates, where superplastic behaviour has been inferred. To a first approximation, the measured drop in strength is in agreement with our flow stress calculations, suggesting that strain could be accommodated more efficiently by these mechanisms within the weaker bulk slip zone, rather than by frictional sliding along the main slip surfaces in the slip zone. Frictionally induced, grainsize-sensitive GBS deformation mechanisms can thus account for the self-lubrication and dynamic weakening of carbonate faults during earthquake propagation in nature.

The Mechanical Property of Batch Annealed High Strength Low Alloy Steel HC260LA

NASA Astrophysics Data System (ADS)

Yang, Xiaojiang; Xia, Mingsheng; Zhang, Hongbo; Han, Bin; Li, Guilan

Cold rolled high strength low alloy steel is widely applied in the automotive parts due to its excellent formability and weldability. In this paper, the steel grade HC260LA according to European Norm was developed with batch annealing process. With commercial C-Mn mild steel as a benchmark, three different groups of chemistry namely C-Mn-Si, C-Mn-Nb-Ti and C-Mn-Nb were compared in terms of yield-tensile strength (Y/T) ratio. Microstructure and mechanical properties were characterized as well. Based on industrial production results, chemistry and detailed process parameters for batch annealing were identified. In the end the optimal Y/T ratio was proposed for this steel grade under batch annealing process.

Low-Temperature Forming of Beta Titanium Alloys

NASA Technical Reports Server (NTRS)

Kaneko, R. S.; Woods, C. A.

1983-01-01

Low cost methods for titanium structural fabrication using advanced cold-formable beta alloys were investigated for application in a Mach 2.7 supersonic cruise vehicle. This work focuses on improving processing and structural efficiencies as compared with standard hot formed and riveted construction of alpha-beta alloy sheet structure. Mechanical property data and manufacturing parameters were developed for cold forming, brazing, welding, and processing Ti-15V-3Cr-3Sn-3Al sheet, and Ti-3Al-8V-6Cr-4Zr on a more limited basis. Cost and structural benefits were assessed through the fabrication and evaluation of large structural panels. The feasibility of increasing structural efficiency of beta titanium structure by selective reinforcement with metal matrix composite was also explored.

An Improvement of the Anisotropy and Formability Predictions of Aluminum Alloy Sheets

NASA Astrophysics Data System (ADS)

Banabic, D.; Comsa, D. S.; Jurco, P.; Wagner, S.; Vos, M.

2004-06-01

The paper presents an yield criterion for orthotropic sheet metals and its implementation in a theoretical model in order to calculate the Forming Limit Curves. The proposed yield criterion has been validated for two aluminum alloys: AA3103-0 and AA5182-0, respectively. The biaxial tensile test of cross specimens has been used for the determination of the experimental yield locus. The new yield criterion has been implemented in the Marciniak-Kuczynski model for the calculus of limit strains. The calculated Forming Limit Curves have been compared with the experimental ones, determined by frictionless test: bulge test, plane strain test and uniaxial tensile test. The predicted Forming Limit Curves using the new yield criterion are in good agreement with the experimental ones.

Formability analysis of austenitic stainless steel-304 under warm conditions

NASA Astrophysics Data System (ADS)

Lade, Jayahari; Singh, Swadesh Kumar; Banoth, Balu Naik; Gupta, Amit Kumar

2013-12-01

A warm deep drawing process of austenitic stainless steel-304 (ASS-304) of circular blanks with coupled ther mal analysis is studied in this article. 65 mm blanks were deep drawn at different temperatures and thickness distribution is experimentally measured after cutting the drawn component into two halves. The process is simulated using explicit fin ite element code LS-DYNA. A Barlat 3 parameter model is used in the simulation, as the material is anisotropic up to 30 0°C. Material properties for the simulation are determined at different temperatures using a 5 T UTM coupled with a furn ace. In this analysis constant punch speed and variable blank holder force (BHF) is applied to draw cups without wrinkle.

Characterisation of Ductile Prepregs

NASA Astrophysics Data System (ADS)

Pinto, F.; White, A.; Meo, M.

2013-04-01

This study is focused on the analysis of micro-perforated prepregs created from standard, off the shelf prepregs modified by a particular laser process to enhance ductility of prepregs for better formability and drapability. Fibres are shortened through the use of laser cutting in a predetermined pattern intended to maintain alignment, and therefore mechanical properties, yet increase ductility at the working temperature. The increase in ductility allows the product to be more effectively optimised for specific forming techniques. Tensile tests were conducted on several specimens in order to understand the ductility enhancement offered by this process with different micro-perforation patterns over standard prepregs. Furthermore, the effects of forming temperature was also analysed to assess the applicability of this material to hot draping techniques and other heated processes.

Damage and Failure Analysis of AZ31 Alloy Sheet in Warm Stamping Processes

NASA Astrophysics Data System (ADS)

Zhao, P. J.; Chen, Z. H.; Dong, C. F.

2016-07-01

In this study, a combined experimental-numerical investigation on the failure of AZ31 Mg alloy sheet in the warm stamping process was carried out based on modified GTN damage model which integrated Yld2000 anisotropic yield criterion. The constitutive equations of material were implemented into a VUMAT subroutine for solver ABAQUS/Explicit and applied to the formability analysis of mobile phone shell. The morphology near the crack area was observed using SEM, and the anisotropic damage evolution at various temperatures was simulated. The distributions of plastic strain, damage evolution, thickness, and fracture initiation obtained from FE simulation were analyzed. The corresponding forming limit diagrams were worked out, and the comparison with the experimental data showed a good agreement.

Development of Microalloyed Steels for The Oil and Gas Industry

NASA Astrophysics Data System (ADS)

Henein, H.; Ivey, D. G.; Luo, J.; Wiskel, J. B.

Microalloying, in combination with thermomechanical controlled processing (TMCP), is a cost effective method of producing steels for a wide range of applications where improved mechanical properties, namel y strength, formability and toughness coupled with weldability, are required. This paper reviews the efforts undertaken at the University of Alberta aimed at improving the above mentioned mechanical properties in microalloyed steels used in the transmission of oil and gas (i.e., pipelines). Topics that will be reviewed include the characterization of precipitates, the effect of processing conditions on precipitate evolution, and the effect of pipe forming and subsequent low temperature heat treatment on tensile behaviour and the use of Genetic Algorithm optimization of the laminar cooling system to produce a uniform through thickness microstructure.

Finite Element Modeling, Simulation, Tools, and Capabilities at Superform

NASA Astrophysics Data System (ADS)

Raman, Hari; Barnes, A. J.

2010-06-01

Over the past thirty years Superform has been a pioneer in the SPF arena, having developed a keen understanding of the process and a range of unique forming techniques to meet varying market needs. Superform’s high-profile list of customers includes Boeing, Airbus, Aston Martin, Ford, and Rolls Royce. One of the more recent additions to Superform’s technical know-how is finite element modeling and simulation. Finite element modeling is a powerful numerical technique which when applied to SPF provides a host of benefits including accurate prediction of strain levels in a part, presence of wrinkles and predicting pressure cycles optimized for time and part thickness. This paper outlines a brief history of finite element modeling applied to SPF and then reviews some of the modeling tools and techniques that Superform have applied and continue to do so to successfully superplastically form complex-shaped parts. The advantages of employing modeling at the design stage are discussed and illustrated with real-world examples.

Directional solidification of eutectic composites in space environment

NASA Technical Reports Server (NTRS)

Yue, A. S.

1972-01-01

The Ni-Ni3Ta eutectic and a nickel-base alloy containing 30 wt pct Ta were solidified unidirectionally in an electron beam floating zone melting apparatus. It was found that the volume fraction of the Ni3Ta phase in the Ni-Ni3Ta eutectic mixture was increased from 7.6 to 36 volume pct in agreement with the theory as predicted. Tensile properties of the randomly solidified and unidirectionally solidified Ni-Ni3Ta eutectic were determined as function of solidification rate and temperature. It was found that the ultimate tensile strength decreased as both the test temperature and solidification rate increased. An elongation of 40 pct was obtained for a nickelbase alloy containing 30 wt at room temperature. This unusually large elongation was attributed to the superplastic behavior of the alloy. The critical currents versus the external fields at 2.5, 3.0, 3.5 and 4.2 deg for the unidirectionally solidified Pb-Sn eutectic were measured. The values of critical fields at zero critical currents were obtained by extrapolation.

JPRS report: Science and technology. Central Eurasia

NASA Astrophysics Data System (ADS)

1994-08-01

Translated articles cover the following topics: boronizing laser treatment of titanium alloys; argon-arc welding-on titanium dowels to inserts for aircraft structures made of composite materials; method of reducing level of thermally stressed state of gas turbine engine blades by selecting optimum thickness distribution of ceramic heat shield coating; certifying modern ceramics for mechanical properties; superplastic ceramic: possibilities for application in modeling pressworking manufacturing processes; monitoring strength of ceramics by acoustic emission; physical and mechanical properties of Al2O3 + ZrO2:Y2O3 composite produced by directional crystallization from melt; influence that microalloying with rare earth elements has on resistance of steels to deformation and fracture under alternating elastic-plastic loading; conceptions of constructing information management networks for distributed objects; concept of a document information system based on an object-oriented subject-area model; underground future of rocket technologies; geoinformation approach to organizing automated information systems for regional-local monitoring of atmospheric pollutants; and possibility of using lidar wind sounding in climatic-ecologic monitoring of limited areas.

Low cost, SPF aluminum cryogenic tank structure for ALS

NASA Technical Reports Server (NTRS)

Anton, Claire E.; Rasmussen, Perry; Thompson, Curt; Latham, Richard; Hamilton, C. Howard; Ren, Ben; Gandhi, Chimata; Hardwick, Dallis

1992-01-01

Past production work has shown that cryogenic tank structure for the Shuttle Booster Rockets and the Titan system have very high life cycle costs for the fuel tank structure. The tanks are machined stiffener-skin combination that are subsequently formed into the required contour after machining. The material scrap rate for these configurations are usually high, and the loss of a tank panel due to forming or heat treatment problems is very costly. The idea of reducing the amount of scrap material and scrapped structural members has prompted the introduction of built-up structure for cryogenic tanks to be explored on the ALS program. A build-up structure approach that has shown improvements in life cycle cost over the conventional built-up approach is the use of superplastically formed (SPF) stiffened panels (reducing the overall part count and weight for the tank) resistance spot welded (RSW) to outer tank skin material. The stiffeners provide for general stability of the tank, while the skin material provides hoop direction continuity for the loads.

Ductile all-cellulose nanocomposite films fabricated from core-shell structured cellulose nanofibrils.

PubMed

Larsson, Per A; Berglund, Lars A; Wågberg, Lars

2014-06-09

Cellulosic materials have many desirable properties such as high mechanical strength and low oxygen permeability and will be an important component in a sustainable biomaterial-based society, but unfortunately they often lack the ductility and formability offered by petroleum-based materials. This paper describes the fabrication and characterization of nanocomposite films made of core-shell modified cellulose nanofibrils (CNFs) surrounded by a shell of ductile dialcohol cellulose, created by heterogeneous periodate oxidation followed by borohydride reduction of the native cellulose in the external parts of the individual fibrils. The oxidation with periodate selectively produces dialdehyde cellulose, and the process does not increase the charge density of the material. Yet the modified cellulose fibers could easily be homogenized to CNFs. Prior to film fabrication, the CNF was shown by atomic force microscopy to be 0.5-2 μm long and 4-10 nm wide. The films were fabricated by filtration, and besides uniaxial tensile testing at different relative humidities, they were characterized by scanning electron microscopy and oxygen permeability. The strength-at-break at 23 °C and 50% RH was 175 MPa, and the films could, before rupture, be strained, mainly by plastic deformation, to about 15% and 37% at 50% RH and 90% RH, respectively. This moisture plasticization was further utilized to form a demonstrator consisting of a double-curved structure with a nominal strain of 24% over the curvature. At a relative humidity of 80%, the films still acted as a good oxygen barrier, having an oxygen permeability of 5.5 mL·μL/(m(2)·24 h·kPa). These properties indicate that this new material has a potential for use as a barrier in complex-shaped structures and hence ultimately reduce the need for petroleum-based plastics.

Antibacterial effects, biocompatibility and electrochemical behavior of zinc incorporated niobium oxide coating on 316L SS for biomedical applications

NASA Astrophysics Data System (ADS)

Pradeep PremKumar, K.; Duraipandy, N.; Manikantan Syamala, Kiran; Rajendran, N.

2018-01-01

In the present study, Nb2O5 (NZ0) composite coatings with various concentrations of zinc (NZ2, NZ4 & NZ6) are produced on 316L SS by sol-gel method with the aim of improving its antibacterial activity, bone formability and corrosion resistance properties. This work studied the surface characterization of NZ0, NZ2, NZ4 & NZ6 coated 316L SS by ATR-FTIR, XRD, HR-SEM with EDAX. The synthesized coatings were different in the morphological aspects, NZ0 shows mesoporous morphology whereas irregular cluster like morphology was observed for the zinc incorporated coatings. The chemical composition of the NZ0 and NZ4 composite coatings were studied by XPS and the results revealed that the zinc exist as ZnO and Nb as Nb2O5 in the coatings. The increase in the concentration of zinc in Nb2O5 increases the hydrophilic nature identified by water contact angle studies. The potentiodynamic polarization studies in simulated body fluid reveals the increase in polarization resistance with decrease in current density (icorr) and electrochemical impedance spectroscopic studies with increase in charge transfer resistance (Rct) and double layer capacitance (Qdl) were observed for NZ4 coated 316L SS. The inhibition of Staphylococcus aureus and Escherichia coli bacteria were identified for NZ4 coated 316L SS by bacterial viability studies. The NZ4 coated 316L SS showed better Osseo-integration by spreading the MG 63 osteoblast cells. The study results imply that zinc incorporated Nb2O5 (NZ4) composite coating exhibits antibacterial activity and also enhance the corrosion resistance and biocompatibility of the 316L SS.

The Origin of Fracture in the I-ECAP of AZ31B Magnesium Alloy

NASA Astrophysics Data System (ADS)

Gzyl, Michal; Rosochowski, Andrzej; Boczkal, Sonia; Qarni, Muhammad Jawad

2015-11-01

Magnesium alloys are very promising materials for weight-saving structural applications due to their low density, comparing to other metals and alloys currently used. However, they usually suffer from a limited formability at room temperature and low strength. In order to overcome those issues, processes of severe plastic deformation (SPD) can be utilized to improve mechanical properties, but processing parameters need to be selected with care to avoid fracture, very often observed for those alloys during forming. In the current work, the AZ31B magnesium alloy was subjected to SPD by incremental equal-channel angular pressing (I-ECAP) at temperatures varying from 398 K to 525 K (125 °C to 250 °C) to determine the window of allowable processing parameters. The effects of initial grain size and billet rotation scheme on the occurrence of fracture during I-ECAP were investigated. The initial grain size ranged from 1.5 to 40 µm and the I-ECAP routes tested were A, BC, and C. Microstructures of the processed billets were characterized before and after I-ECAP. It was found that a fine-grained and homogenous microstructure was required to avoid fracture at low temperatures. Strain localization arising from a stress relaxation within recrystallized regions, namely twins and fine-grained zones, was shown to be responsible for the generation of microcracks. Based on the I-ECAP experiments and available literature data for ECAP, a power law between the initial grain size and processing conditions, described by a Zener-Hollomon parameter, has been proposed. Finally, processing by various routes at 473 K (200 °C) revealed that route A was less prone to fracture than routes BC and C.

Development of Aluminum-Lithium 2195 Gores by the Stretch Forming Process

NASA Technical Reports Server (NTRS)

Volz, M. P.; Chen, P. S.; Gorti, S.; Salvail, P.

2014-01-01

Aluminum-Lithium alloy 2195 exhibits higher mechanical properties and lower density than aluminum alloy 2219, which is the current baseline material for Space Launch System (SLS) cryogenic tank components. Replacement of Al 2219 with Al-Li 2195 would result in substantial weight savings, as was the case when this replacement was made on the shuttle external tank. A key component of cryogenic tanks are the gores, which are welded together to make the rounded ends of the tanks. The required thicknesses of these gores depend on the specific SLS configuration and may exceed the current experience base in the manufacture of such gores by the stretch forming process. Here we describe the steps taken to enhance the formability of Al-Li 2195 by optimizing the heat treatment and stretch forming processes for gore thicknesses up to 0.75", which envelopes the maximum expected gore thicknesses for SLS tanks. An annealing treatment, developed at Marshall Space Flight Center, increased the forming range and strain hardening exponent of Al-Li 2195 plates. Using this annealing treatment, one 0.525" thick and two 0.75" thick gores were manufactured by the stretch forming process. The annealing treatment enabled the stretch forming of the largest ever cross sectional area (thickness x width) of an Al-Li 2195 plate achieved by the manufacturer. Mechanical testing of the gores showed greater than expected ultimate tensile strength, yield strength, modulus, and elongation values. The gores also exhibited acceptable fracture toughness at room and LN2 temperatures. All of the measured data indicate that the stretch formed gores have sufficient material properties to be used in flight domes.

Surface bioactivity modification of titanium by CO 2 plasma treatment and induction of hydroxyapatite: In vitro and in vivo studies

NASA Astrophysics Data System (ADS)

Hu, Xixue; Shen, Hong; Shuai, Kegang; Zhang, Enwei; Bai, Yanjie; Cheng, Yan; Xiong, Xiaoling; Wang, Shenguo; Fang, Jing; Wei, Shicheng

2011-01-01

Since metallic biomaterials used for orthopedic and dental implants possess a paucity of reactive functional groups, bioactivity modification of these materials is challenging. In the present work, the titanium discs and rods were treated with carbon dioxide plasma and then incubated in a modified simulated body fluid 1.5SBF to obtain a hydroxyapatite layer. Surface hydrophilicity of samples, changes of surface chemistry, surface morphologies of samples, and structural analysis of formed hydroxyapatite were investigated by contact angle to water, X-ray photoelectron spectrometer (XPS), scanning electron microscopy (SEM), Fourier transform infrared (FTIR) and X-ray diffraction (XRD). The results demonstrated that hydrophilicity of titanium surface was improved and hydroxyl groups increased after modification with carbon dioxide plasma treatment. The hydroxyl groups on the surface of titanium were the richest after carbon dioxide plasma treatment under the condition of 20 W for less than 30 s. The hydroxyapatite formability of titanium surface was enhanced by carbon dioxide plasma pretreatment, which was attributed to the surface chemistry. MC3T3-E1 cell as a model cell was cultured on the Ti, CPT-Ti and CPT/SBF-Ti discs in vitro, and the results of the morphology and differentiation of the cell showed that CPT/SBF-Ti was the highest bioactive. The relative parameters of the new bone around the Ti and CPT/SBF-Ti rods including bone mineral density (BMD), a ratio of bone volume to total volume (BV/TV), trabecular thickness (Tb.Th.) and trabecular number (Tb.N.) were analyzed by a micro-computed tomography (micro-CT) after 4-, 8- and 12-week implantation periods in vivo. The results indicated that the CPT/SBF-Ti was more advantageous for new bone formation.

Controlled rolling process for dual phase steels and application to rod, wire, sheet and other shapes

DOEpatents

Thomas, G.; Ahn, J.H.; Kim, N.J.

1986-10-28

An improved, energy efficient, hot rolling method for direct production of cold formable dual-phase steel is provided. The steel is heated to completely austenitize it and then continuously hot rolled and cooled down into the ferrite-austenite two phase region to a temperature which is just below the effective Ar[sub 3] temperature. The hot rolled steel is then rapidly quenched to provide an alloy containing strong, tough lath martensite (fibers) in a ductile soft ferrite matrix. The method is particularly useful for providing rods in which form the alloy is capable of being drawn into high strength wire or the like in a cold drawing operation without any intermediate annealing or patenting, and has excellent strength, ductility and fatigue characteristics. 3 figs.

Controlled rolling process for dual phase steels and application to rod, wire, sheet and other shapes

DOEpatents

Thomas, Gareth; Ahn, Jae-Hwan; Kim, Nack-Joon

1986-01-01

An improved, energy efficient, hot rolling method for direct production of cold formable dual-phase steel is provided. The steel is heated to completely austenitize it and then continuously hot rolled and cooled down into the ferrite-austenite two phase region to a temperature which is just below the effective Ar.sub.3 temperature. The hot rolled steel is then rapidly quenched to provide an alloy containing strong, tough lath martensite (fibers) in a ductile soft ferrite matrix. The method is particularly useful for providing rods in which form the alloy is capable of being drawn into high strength wire or the like in a cold drawing operation without any intermediate annealing or patenting, and has excellent strength, ductility and fatigue characteristics.

The rolling performance of Fe-6.5 wt.% Si sheets edged with stainless steel

NASA Astrophysics Data System (ADS)

Zhang, B.; Ye, F.; Liang, Y. F.; Shi, X. J.; Lin, J. P.

2017-10-01

Compared with common electrical steel, high silicon electrical steel (Fe-6.5 wt.% Si alloy) exhibits excellent soft magnetic properties and a wide application prospect in high frequency electromagnetic fields. In the process of cold rolling Fe-6.5 wt.% Si alloy, edge-crack often occurs on the sheets due to the inadequate ductility and limited formability. It was found that the Fe-6.5 wt.% Si alloy sheet edged with 304 stainless steel by laser welding show an improved rolling performance. The composite sheet could be cold rolled to a thickness of 0.07 mm without observed edge cracks. The mechanical property of the edging material should be in an appropriate window in reference to that of the Fe-6.5 wt.% Si alloy.

Shear Fracture of Dual Phase AHSS in the Process of Stamping: Macroscopic Failure Mode and Micro-level Metallographical Observation

NASA Astrophysics Data System (ADS)

Wang, Wurong; Wei, Xicheng; Yang, Jun; Shi, Gang

2011-08-01

Due to its excellent strength and formability combinations, dual phase (DP) steels offer the potential to improve the vehicle crashworthiness performance without increasing car body weight and have been increasingly used into new vehicles. However, a new type of crack mode termed as shear fracture is accompanied with the application of these high strength DP steel sheets. With the cup drawing experiment to identify the limit drawing ratio (LDR) of three DP AHSS with strength level from 600 MPa to 1000 MPa, the study compared and categorized the macroscopic failure mode of these three types of materials. The metallographical observation along the direction of crack was conducted for the DP steels to discover the micro-level propagation mechanism of the fracture.

Size-Dependent Brittle-to-Ductile Transition in Silica Glass Nanofibers.

PubMed

Luo, Junhang; Wang, Jiangwei; Bitzek, Erik; Huang, Jian Yu; Zheng, He; Tong, Limin; Yang, Qing; Li, Ju; Mao, Scott X

2016-01-13

Silica (SiO2) glass, an essential material in human civilization, possesses excellent formability near its glass-transition temperature (Tg > 1100 °C). However, bulk SiO2 glass is very brittle at room temperature. Here we show a surprising brittle-to-ductile transition of SiO2 glass nanofibers at room temperature as its diameter reduces below 18 nm, accompanied by ultrahigh fracture strength. Large tensile plastic elongation up to 18% can be achieved at low strain rate. The unexpected ductility is due to a free surface affected zone in the nanofibers, with enhanced ionic mobility compared to the bulk that improves ductility by producing more bond-switching events per irreversible bond loss under tensile stress. Our discovery is fundamentally important for understanding the damage tolerance of small-scale amorphous structures.

Linear complexions: Confined chemical and structural states at dislocations

NASA Astrophysics Data System (ADS)

Kuzmina, M.; Herbig, M.; Ponge, D.; Sandlöbes, S.; Raabe, D.

2015-09-01

For 5000 years, metals have been mankind’s most essential materials owing to their ductility and strength. Linear defects called dislocations carry atomic shear steps, enabling their formability. We report chemical and structural states confined at dislocations. In a body-centered cubic Fe-9 atomic percent Mn alloy, we found Mn segregation at dislocation cores during heating, followed by formation of face-centered cubic regions but no further growth. The regions are in equilibrium with the matrix and remain confined to the dislocation cores with coherent interfaces. The phenomenon resembles interface-stabilized structural states called complexions. A cubic meter of strained alloy contains up to a light year of dislocation length, suggesting that linear complexions could provide opportunities to nanostructure alloys via segregation and confined structural states.

Single Point Incremental Forming to increase material knowledge and production flexibility

NASA Astrophysics Data System (ADS)

Habraken, A. M.

2016-08-01

Nowadays, manufactured pieces can be divided into two groups: mass production and production of low volume number of parts. Within the second group (prototyping or small batch production), an emerging solution relies on Incremental Sheet Forming or ISF. ISF refers to processes where the plastic deformation occurs by repeated contact with a relatively small tool. More specifically, many publications over the past decade investigate Single Point Incremental Forming (SPIF) where the final shape is determined only by the tool movement. This manufacturing process is characterized by the forming of sheets by means of a CNC controlled generic tool stylus, with the sheets clamped by means of a non-workpiece-specific clamping system and in absence of a partial or a full die. The advantage is no tooling requirements and often enhanced formability, however it poses a challenge in term of process control and accuracy assurance. Note that the most commonly used materials in incremental forming are aluminum and steel alloys however other alloys are also used especially for medical industry applications, such as cobalt and chromium alloys, stainless steel and titanium alloys. Some scientists have applied incremental forming on PVC plates and other on sandwich panels composed of propylene with mild steel and aluminum metallic foams with aluminum sheet metal. Micro incremental forming of thin foils has also been developed. Starting from the scattering of the results of Finite Element (FE) simulations, when one tries to predict the tool force (see SPIF benchmark of 2014 Numisheet conference), we will see how SPIF and even micro SPIF (process applied on thin metallic sheet with a few grains within the thickness) allow investigating the material behavior. This lecture will focus on the identification of constitutive laws, on the SPIF forming mechanisms and formability as well as the failure mechanism. Different hypotheses have been proposed to explain SPIF formability, they will be listed however the lecture will be more focused on the use of SPIF to identify material parameters of well-chosen constitutive law. Results of FE simulations with damage models will be investigated to better understand the relation between the particular stress and strain states in the material during SPIF and the material degradation leading to localization or fracture. Last but not least, as industrial world does not wait that academic scientists provide a deep and total understanding on how it works, to use interesting processes, the lecture will review some applications. Examples in fields as different as automotive guard, engine heat shield, gas turbine, electronic sensor, shower basin, medical component (patient-fitted organic shapes) and architecture demonstrate that the integration of SPIF within the industry is more and more a reality. Note that this plenary lecture is the result of the research performed by the author in the University of Liege (Belgium) and in Aveiro (Portugal) with the team of R. de Souza during PhD theses of C. Henrard, J. Sena and C. Guzman and different research projects. It is also a synthesis of the knowledge gathered during her interactions with many research teams such as the ones of J.R. Duflou from KU Leuven in Belgium, J. Cao from Northwestern University in USA, M. Bambach in BTU Cottbus-Senftenberg in Germany, J. Jeswiet from Queen's University, Kingston, Canada who are currently working together on a state-of-the-art paper. The micro SPIF knowledge relies on contacts with S. Thibaud from the University of Franche Comte.

Relations and interactions between twinning and grain boundaries in hexagonal close-packed structures

NASA Astrophysics Data System (ADS)

Barrett, Christopher Duncan

Improving the formability and crashworthiness of wrought magnesium alloys are the two biggest challenges in current magnesium technology. Magnesium is the best material candidate for enabling required improvements in fuel economy of combustion engines and increases in ranges of electric vehicles. In hexagonal closed-packed (HCP) structures, effects of grain size/morphology and crystallographic texture are particularly important. Prior research has established a general understanding of the dependences of strength and strain anisotropy on grain morphology and texture. Unfortunately, deformation, recrystallization, and grain growth strategies that control the microstructures and textures of cubic metals and alloys have not generally worked for HCPs. For example, in Magnesium, the deformation texture induced by primary forming operations (rolling, extrusion, etc.) is not randomized by recrystallization and may strengthen during grain growth. A strong texture reduces formability during secondary forming (stamping, bending, hemming etc.) Thus, the inability to randomize texture has impeded the implementation of magnesium alloys in engineering applications. When rare earth solutes are added to magnesium alloys, distinct new textures are derived. However, `rare earth texture' derivation remains insufficiently explained. Currently, it is hypothesized that unknown mechanisms of alloy processing are at work, arising from the effects of grain boundary intrinsic defect structures on microstructural evolution. This dissertation is a comprehensive attempt to identify formal methodologies of analyzing the behavior of grain boundaries in magnesium. We focus particularly on twin boundaries and asymmetric tilt grain boundaries using molecular dynamics. We begin by exploring twin nucleation in magnesium single crystals, elucidating effects of heterogeneities on twin nucleation and their relationships with concurrent slip. These efforts highlighted the necessity of imperfections to nucleate {10-12} twins. Subsequent studies encountered the importance of deformation faceting on the high mobility of {10-12} and stabilization of observed twin mode boundaries. Implementation of interfacial defect theory was necessary to decipher the complex mechanisms observed which govern the development of defects in grain boundaries, disconnection pile-up, facet nucleation, interfacial disclination nucleation, disconnection movements, disconnection transformation across interfacial disclinations, cross-faceting, and byproducts of interactions between lattice dislocations and grain boundaries.

Microplastic bases for constitutive characterization of aluminum alloys and their correlation to sheet formability

NASA Astrophysics Data System (ADS)

Diak, Bradley James

Forming limit predictions that incorporate crystal plasticity models still cannot adequately predict the deformation performance of polycrystalline materials. The reason for the limitation in predictive power is that the constitutive equations used to connect to the atomic scale assume an affine deformation which do not have a physical basis, but give general trends. This study was undertaken to better elucidate the microplastic process and how it manifests itself phenomenologically. In this endeavour, the strain rate sensitivity of the flow stress was identified as one parameter that greatly affects the forming limit. Hence, an attempt was made to properly define and measure the strain rate sensitivity according to the dictates of thermodynamics. The thermodynamics of systems can delineate the evolution of the state of a material if the state variables can be characterized and measured. Inevitably, these variables must be determined at constant structure. Using the theory of thermally activated flow, where the movement of dislocations past obstacles is the rate controlling step, the mechanical testing techniques have been designed to statistically assess the dynamic evolution of the microstructure by controlling the temperature, T, and strain rate, dotvarepsilon, and measuring the stress, sigma, mean slip distance, lambda, and mean slip velocity, dotlambda, to define sigma=f(lambda,dotlambda, T). The apparent activation volume, which characterizes the obstacle resistance of strain centres, is determined at constant structure by applying the strain rate change technique. Strain rate sensitivity data are compared to the Cottrell-Stokes relation, and the Haasen plot is used to separate the different contributions to the flow stress. Using these precise measurements at interrupted segments of strain, the evolution of a microstructure during plastic flow can be monitored. By this examination of different rate controlling obstacles, the microstructural parameters which correlate to formability were assessed. Detailed experimental evidence is given for different aluminum alloys containing mainly fast or slow diffusing solute species, transition precipitates, dispersed particles, and/or dislocation debris. These systems of Al-Fe, Al-Cr, Al-Cu, Al-Mg, and Al-Mg-Si, all displayed unique dislocation-defect interactions which could be elucidated by the current theory of thermally activated flow.

Crystal plasticity assisted prediction on the yield locus evolution and forming limit curves

NASA Astrophysics Data System (ADS)

Lian, Junhe; Liu, Wenqi; Shen, Fuhui; Münstermann, Sebastian

2017-10-01

The aim of this study is to predict the plastic anisotropy evolution and its associated forming limit curves of bcc steels purely based on their microstructural features by establishing an integrated multiscale modelling approach. Crystal plasticity models are employed to describe the micro deformation mechanism and correlate the microstructure with mechanical behaviour on micro and mesoscale. Virtual laboratory is performed considering the statistical information of the microstructure, which serves as the input for the phenomenological plasticity model on the macroscale. For both scales, the microstructure evolution induced evolving features, such as the anisotropic hardening, r-value and yield locus evolution are seamlessly integrated. The predicted plasticity behaviour by the numerical simulations are compared with experiments. These evolutionary features of the material deformation behaviour are eventually considered for the prediction of formability.

Development of a Hybrid Deep Drawing Process to Reduce Springback of AHSS

NASA Astrophysics Data System (ADS)

Boskovic, Vladimir; Sommitsch, Christoph; Kicin, Mustafa

2017-09-01

In future, the steel manufacturers will strive for the implementation of Advanced High Strength Steels (AHSS) in the automotive industry to reduce mass and improve structural performance. A key challenge is the definition of optimal and cost effective processes as well as solutions to introduce complex steel products in cold forming. However, the application of these AHSS often leads to formability problems such as springback. One promising approach in order to minimize springback is the relaxation of stress through the targeted heating of materials in the radius area after the deep drawing process. In this study, experiments are conducted on a Dual Phase (DP) and TWining Induced Plasticity (TWIP) steel for the process feasibility study. This work analyses the influence of various heat treatment temperatures on the springback reduction of deep drawn AHSS.

A study on the development of engineering plastic piston used in the shock absorber

NASA Astrophysics Data System (ADS)

Kim, Young-Ho; Bae, Won-Byong; Lim, Dong-Ju; Suh, Yun-Soo

1998-08-01

A piston is an important component of the shock absorber which determines comfortable riding and handling. Conventional piston is made of metal powder that is pressed in a mold, and then sintered at high temperatures below the melting point before machining processes such as drilling, sizing and teflon banding. This study aims at cutting down cost and weight, and improving the process by replacing the traditional sintering process used for manufacturing the shock absorber with the injection molding process adopting engineering plastics as raw material. To analyze the injection molding process, we used the commercial program, MOLDFLOW, and obtained an optimal combination of the process parameters. In addition, by comparing the engineering plastic piston with the metal powder piston through the formability and the performance experiments, we confirmed the availability of this alternative process suggested.

Effects of Testing Method on Stretch-Flangeability of Dual-Phase 980/1180 Steel Grades

NASA Astrophysics Data System (ADS)

Madrid, Mykal; Van Tyne, Chester J.; Sadagopan, Sriram; Pavlina, Erik J.; Hu, Jun; Clarke, Kester D.

2018-04-01

Challenging fuel economy and safety standards in the automotive industry have led to the need for materials with higher strength while maintaining levels of formability that meet component manufacturing requirements. Advanced high-strength steels, such as dual-phase steels with tensile strengths of 980 MPa and 1180 MPa, are of interest to address this need. Increasing the strength of these materials typically comes at the expense of ductility, which may result in problems when stamping parts with trimmed or sheared edges, as cracking at the sheared edge may occur at lower strains. Here, hole expansion tests were performed with different punch geometries (conical and flat-bottom) and different edge conditions (sheared and machined) to understand the effects of testing conditions on performance, and these results are discussed in terms of mechanical properties and microstructures.

Optimization of the Processing Parameters of High Temperature Superconducting Glass-Ceramics: Center Director's Discretionary Fund Final Report

NASA Technical Reports Server (NTRS)

Ethridge, E. C.; Kaukler, W. F.

1993-01-01

A number of promising glass forming compositions of high Tc superconducting Ba-Sr-Ca-Cu-O (BSCCO) materials were evaluated for their glass-ceramic crystallization ability. The BSCCO ceramics belonging to the class of superconductors in the Ba-Sr-Ca-Cu-O system were the focus of this study. By first forming the superconducting material as a glass, subsequent devitrification into the crystalline (glass-ceramic) superconductor can be performed by thermal processing of the glass preform body. Glass formability and phase formation were determined by a variety of methods in another related study. This study focused on the nucleation and crystallization of the materials. Thermal analysis during rapid cooling aids in the evaluation of nucleation and crystallization behavior. Melt viscosity is used to predict glass formation ability.

The Work Softening Behavior of Pure Mg Wire during Cold Drawing.

PubMed

Sun, Liuxia; Bai, Jing; Xue, Feng; Chu, Chenglin; Meng, Jiao

2018-04-13

We performed multiple-pass cold drawing for pure Mg wire which showed excellent formability (~138% accumulative true strain) at room temperature. Different from the continuous work hardening occurring during cold drawing of Mg alloy wires, for pure Mg, an initially rapid increase in hardness and strength was followed by significant work softening and finally reached a steady-state level, approximately 40~45 HV. The work softening can be attributed to the dynamic recovery and recrystallization of pure Mg at room temperature. Meanwhile, an abrupt change in texture component also was detected with the transition from work hardening to softening in the strain range of 28~34%. During the whole drawing, the strongest texture component gradually transformed from as-extruded basal to <10 1 ¯ 0> fiber (~28% accumulative true strain), and then rapidly returned to the weak basal texture.

Current and Future Uses of Aluminum in the Automotive Industry

NASA Astrophysics Data System (ADS)

Long, R. S.; Boettcher, E.; Crawford, D.

2017-12-01

Aluminum use is growing in automotive closures and body in white applications to improve vehicle performance and fuel economy. The auto industry is looking for higher-strength aluminum materials needed for strength-driven safety-critical parts. Through cooperation with industrial partners and support from the Department of Energy (DOE), multiple experimental 7xxx alloys were developed for automotive applications. The objective is to enable complex shapes to be formed at temperatures below 225°C. A demonstration part has been developed that is representative of the forming challenges within a current hot-stamped door ring component. This part tooling has been built and installed into a press line which includes blank heating and robotic transfer. Forming trials of these alloys are currently underway and the formability, strength and corrosion performance of these materials are being evaluated.

Effect of Carbon Nanotube on High-Temperature Formability of AZ31 Magnesium Alloy

NASA Astrophysics Data System (ADS)

Hassan, S. Fida; Paramsothy, M.; Gasem, Z. M.; Patel, F.; Gupta, M.

2014-08-01

Room-temperature tensile properties of AZ31 alloy have significantly been improved when reinforced with carbon nanotube via ingot metallurgy process. However, high-temperature (up to 250 °C) elongation-to-failure tensile test of the developed nanocomposite revealed a considerable softening in the AZ31 alloy matrix accompanied by an incredible ductility increment (up to 132%). Microstructural characterization of the fractured samples revealed that the dynamic recrystallization process has induced a complete recrystallization in the AZ31 alloy at a lower temperature (150 °C) followed by substantial grain growth at a higher temperature used in this study. Fractography on the fractured surfaces revealed that the room-temperature mixed brittle-ductile modes of fracture behavior of AZ31 alloy have transformed into a complete ductile mode of fracture at high temperature.

Current and Future Uses of Aluminum in the Automotive Industry

DOE PAGES

Long, R. S.; Boettcher, E.; Crawford, D.

2017-08-29

Aluminum use is growing in automotive closures and body in white applications to improve vehicle performance and fuel economy. The auto industry is looking for higher strength aluminum materials needed for strength driven safety critical parts. Through cooperation with industrial partners and support from the Department of Energy (DOE), multiple experimental 7xxx alloys were developed for automotive applications. The objective is to enable complex shapes to be formed at temperatures below 225° C. A demonstration part has been developed that is representative of the forming challenges within a current hot stamped door ring component. This part tooling has been builtmore » and installed into a press line which includes blank heating and robotic transfer. Forming trials of these alloys are currently underway and the formability, strength and corrosion performance of these materials are being evaluated.« less

Linear complexions: Confined chemical and structural states at dislocations.

PubMed

Kuzmina, M; Herbig, M; Ponge, D; Sandlöbes, S; Raabe, D

2015-09-04

For 5000 years, metals have been mankind's most essential materials owing to their ductility and strength. Linear defects called dislocations carry atomic shear steps, enabling their formability. We report chemical and structural states confined at dislocations. In a body-centered cubic Fe-9 atomic percent Mn alloy, we found Mn segregation at dislocation cores during heating, followed by formation of face-centered cubic regions but no further growth. The regions are in equilibrium with the matrix and remain confined to the dislocation cores with coherent interfaces. The phenomenon resembles interface-stabilized structural states called complexions. A cubic meter of strained alloy contains up to a light year of dislocation length, suggesting that linear complexions could provide opportunities to nanostructure alloys via segregation and confined structural states. Copyright © 2015, American Association for the Advancement of Science.

Cooling rate dependence of structural order in Al90Sm10 metallic glass

NASA Astrophysics Data System (ADS)

Sun, Yang; Zhang, Yue; Zhang, Feng; Ye, Zhuo; Ding, Zejun; Wang, Cai-Zhuang; Ho, Kai-Ming

2016-07-01

The atomic structure of Al90Sm10 metallic glass is studied using molecular dynamics simulations. By performing a long sub-Tg annealing, we developed a glass model closer to the experiments than the models prepared by continuous cooling. Using the cluster alignment method, we found that "3661" cluster is the dominating short-range order in the glass samples. The connection and arrangement of "3661" clusters, which define the medium-range order in the system, are enhanced significantly in the sub-Tg annealed sample as compared with the fast cooled glass samples. Unlike some strong binary glass formers such as Cu64.5Zr35.5, the clusters representing the short-range order do not form an interconnected interpenetrating network in Al90Sm10, which has only marginal glass formability.

The Mechanical Behavior of Friction-Stir Spot Welded Aluminum Alloys

NASA Astrophysics Data System (ADS)

Güler, Hande

2014-10-01

Aluminum and alloys are widely used in the automotive industry due to the light weight, good formability, and malleability. Spot welding is the most commonly used joining method of these materials, but the high current requirements and the inconsistent quality of the final welds make this process unsuitable. An alternative welding technique, the friction-stir spot welding process, can also be successfully used in joining of aluminum and alloys. In this study, 1-mm-thick AA5754 Al-alloy plates in the H-111 temper conditions were joined by friction-stir spot welding using two different weld parameters such as tool rotational speed and dwell time. Mechanical properties of the joints were obtained with extensive hardness measurements and tensile shear tests. The effect of these parameters on the failure modes of welded joints was also determined.

Effects of Testing Method on Stretch-Flangeability of Dual-Phase 980/1180 Steel Grades

NASA Astrophysics Data System (ADS)

Madrid, Mykal; Van Tyne, Chester J.; Sadagopan, Sriram; Pavlina, Erik J.; Hu, Jun; Clarke, Kester D.

2018-06-01

Challenging fuel economy and safety standards in the automotive industry have led to the need for materials with higher strength while maintaining levels of formability that meet component manufacturing requirements. Advanced high-strength steels, such as dual-phase steels with tensile strengths of 980 MPa and 1180 MPa, are of interest to address this need. Increasing the strength of these materials typically comes at the expense of ductility, which may result in problems when stamping parts with trimmed or sheared edges, as cracking at the sheared edge may occur at lower strains. Here, hole expansion tests were performed with different punch geometries (conical and flat-bottom) and different edge conditions (sheared and machined) to understand the effects of testing conditions on performance, and these results are discussed in terms of mechanical properties and microstructures.

Current and Future Uses of Aluminum in the Automotive Industry

DOE Office of Scientific and Technical Information (OSTI.GOV)

Long, R. S.; Boettcher, E.; Crawford, D.

Aluminum use is growing in automotive closures and body in white applications to improve vehicle performance and fuel economy. The auto industry is looking for higher strength aluminum materials needed for strength driven safety critical parts. Through cooperation with industrial partners and support from the Department of Energy (DOE), multiple experimental 7xxx alloys were developed for automotive applications. The objective is to enable complex shapes to be formed at temperatures below 225° C. A demonstration part has been developed that is representative of the forming challenges within a current hot stamped door ring component. This part tooling has been builtmore » and installed into a press line which includes blank heating and robotic transfer. Forming trials of these alloys are currently underway and the formability, strength and corrosion performance of these materials are being evaluated.« less

Development and analysis of a STOL supersonic cruise fighter concept

NASA Technical Reports Server (NTRS)

Dollyhigh, S. M.; Foss, W. E., Jr.; Morris, S. J., Jr.; Walkley, K. B.; Swanson, E. E.; Robins, A. W.

1984-01-01

The application of advanced and emerging technologies to a fighter aircraft concept is described. The twin-boom fighter (TBF-1) relies on a two dimensional vectoring/reversing nozzle to provide STOL performance while also achieving efficient long range supersonic cruise. A key feature is that the propulsion package is placed so that the nozzle hinge line is near the aircraft center-of-gravity to allow large vector angles and, thus, provide large values of direct lift while minimizing the moments to be trimmed. The configurations name is derived from the long twin booms extending aft of the engine to the twin vertical tails which have a single horizontal tail mounted atop and between them. Technologies utilized were an advanced engine (1985 state-of-the-art), superplastic formed/diffusion bonded titanium structure, advanced controls/avionics/displays, supersonic wing design, and conformal weapons carriage. The integration of advanced technologies into this concept indicate that large gains in takeoff and landing performance, maneuver, acceleration, supersonic cruise speed, and range can be acieved relative to current fighter concepts.

Recent progress of tungsten R&D for fusion application in Japan

NASA Astrophysics Data System (ADS)

Ueda, Y.; Lee, H. T.; Ohno, N.; Kajita, S.; Kimura, A.; Kasada, R.; Nagasaka, T.; Hatano, Y.; Hasegawa, A.; Kurishita, H.; Oya, Y.

2011-12-01

The status of ongoing research projects of tungsten R&D in Japan is summarized in this paper. For tungsten material development, a new improved fabrication technique, the so-called superplasticity-based microstructural modification, is described. This technique successfully improved fracture strength and ductility at room temperature. Recent results on vacuum plasma spray W coating and W brazing on ferritic steels and vanadium alloys are explained. Feasibility of these techniques for the manufacture of the blanket is successfully demonstrated. The latest findings on the effect of neutron damage in tungsten on T retention and on the change in mechanical and electrical properties are described. Retention characteristics for neutron-damaged W were different compared to those for ion-damaged W. Upon neutron irradiation, tungsten alloys containing transmutation elements of W (Re and Os) show changes in properties that are different compared with those shown by pure W. The effects of mixed plasma exposure (D/He/C) are described. Both D/He and D/C mixed ion irradiations significantly affect ion-driven permeation in W. He bubble dynamics play a key role in nano-structure formation on the W surface.

NASA-UVA Light Aerospace Alloy and Structures Technology Program (LA2ST)

NASA Technical Reports Server (NTRS)

Gangloff, Richard P.; Scully, John R.; Stoner, Glenn E.; Thornton, Earl A.; Wawner, Franklin E., Jr.; Wert, John A.

1993-01-01

The NASA-UVA Light Aerospace Alloy and Structures Technology (LA2ST) Program continues a high level of activity. Progress achieved between 1 Jan. and 30 Jun. 1993 is reported. The objective of the LA2ST Program is to conduct interdisciplinary graduate student research on the performance of next generation, light weight aerospace alloys, composites, and thermal gradient structures in collaboration with NASA-Langley researchers. The following projects are addressed: environmental fatigue of Al-Li-Cu alloys; mechanisms of localized corrosion and environmental fracture in Al-Cu-Li-Mg-Ag alloy X2095 and compositional variations; the effect of zinc additions on the precipitation and stress corrosion cracking behavior of alloy 8090; hydrogen interactions with Al-Li-Cu alloy 2090 and model alloys; metastable pitting of aluminum alloys; cryogenic fracture toughness of Al-Cu-Li + In alloys; the fracture toughness of Weldalite (TM); elevated temperature cracking of advanced I/M aluminum alloys; response of Ti-1100/SCS-6 composites to thermal exposure; superplastic forming of Weldalite (TM); research to incorporate environmental effects into fracture mechanics fatigue life prediction codes such as NASA FLAGRO; and thermoviscoplastic behavior.

A Microstructure-Based Constitutive Model for Superplastic Forming

NASA Astrophysics Data System (ADS)

Jafari Nedoushan, Reza; Farzin, Mahmoud; Mashayekhi, Mohammad; Banabic, Dorel

2012-11-01

A constitutive model is proposed for simulations of hot metal forming processes. This model is constructed based on dominant mechanisms that take part in hot forming and includes intergranular deformation, grain boundary sliding, and grain boundary diffusion. A Taylor type polycrystalline model is used to predict intergranular deformation. Previous works on grain boundary sliding and grain boundary diffusion are extended to drive three-dimensional macro stress-strain rate relationships for each mechanism. In these relationships, the effect of grain size is also taken into account. The proposed model is first used to simulate step strain-rate tests and the results are compared with experimental data. It is shown that the model can be used to predict flow stresses for various grain sizes and strain rates. The yield locus is then predicted for multiaxial stress states, and it is observed that it is very close to the von Mises yield criterion. It is also shown that the proposed model can be directly used to simulate hot forming processes. Bulge forming process and gas pressure tray forming are simulated, and the results are compared with experimental data.

SPF/DB primary structure for supersonic aircraft (T-38 horizontal stabilizer)

NASA Technical Reports Server (NTRS)

Delmundo, A. R.; Mcquilkin, F. T.; Rivas, R. R.

1981-01-01

The structural integrity and potential cost savings of superplastic forming/diffusion bonding (SPF/DB) titanium structure for future Supersonic Cruise Research (SCR) and military aircraft primary structure applications was demonstrated. Using the horizontal stabilizer of the T-38 aircraft as a baseline, the structure was redesigned to the existing criteria and loads, using SPF/DB titanium technology. The general concept of using a full-depth sandwich structure which is attached to a steel spindle, was retained. Trade studies demonstrated that the optimum design should employ double-truss, sinewave core in the deepest section of the surface, making a transition to single-truss core in the thinner areas at the leading and trailing edges and at the tip. At the extreme thin edges of the surface, the single-truss core was changed to dot core to provide for gas passages during the SPF/DB process. The selected SPF/DB horizontal stabilizer design consisted of a one-piece SPF/DB sinewave truss core panel, a trunnion fitting, and reinforcing straps. The fitting and the straps were mechanically fastened to the SPF/DB panel.

Determination of optimum parameters of the technological process for plates forming from V95 and V-1461 alloys in creep applied in aircrafts constructed by “Sukhoi design bureau”

NASA Astrophysics Data System (ADS)

Raevskaya, G. A.; Zakharchenko, K.; Larichkin, A.

2017-10-01

The research is devoted to the scientific justification of metal processing by pressure with the help of thick monolithic plates forming (thickness 40 mm) from the V95 (analog 7475) (Al-Zn-Mg-Cu) and V-1461 (analog 2099) (Al-Cu-Li-Zn) alloys in creep and close-to-superplasticity. Optimum parameters of the technological process of plate forming are described. The effect of temperature on the magnitude of mechanical stresses (relaxation) during the tests of materials on pure bending is experimentally determined. Forming of thick plates (40 mm) on the UFP-1M unit, and the control of the obtained surface, in comparison with the given electronic model, made it possible to experimentally determine the time and number of forming stages. Mechanical properties of the material after the technological process and heat treatment are preliminary evaluated. The efficiency of using the obtained parameters of the technological process and treatment of metals by pressure in such methods in general is shown.

Cooling rate dependence of structural order in Al 90Sm 10 metallic glass

DOE Office of Scientific and Technical Information (OSTI.GOV)

Sun, Yang; Zhang, Yue; Zhang, Feng

2016-07-07

Here, the atomic structure of Al 90Sm 10 metallic glass is studied using molecular dynamics simulations. By performing a long sub-T g annealing, we developed a glass model closer to the experiments than the models prepared by continuous cooling. Using the cluster alignment method, we found that “3661” cluster is the dominating short-range order in the glass samples. The connection and arrangement of “3661” clusters, which define the medium-range order in the system, are enhanced significantly in the sub-T g annealed sample as compared with the fast cooled glass samples. Unlike some strong binary glass formers such as Cu 64.5Zrmore » 35.5, the clusters representing the short-range order do not form an interconnected interpenetrating network in Al 90Sm 10, which has only marginal glass formability.« less

Cooling rate dependence of structural order in Al{sub 90}Sm{sub 10} metallic glass

DOE Office of Scientific and Technical Information (OSTI.GOV)

Sun, Yang; Ames Laboratory, US Department of Energy, Ames, Iowa 50011; Zhang, Yue

2016-07-07

The atomic structure of Al{sub 90}Sm{sub 10} metallic glass is studied using molecular dynamics simulations. By performing a long sub-T{sub g} annealing, we developed a glass model closer to the experiments than the models prepared by continuous cooling. Using the cluster alignment method, we found that “3661” cluster is the dominating short-range order in the glass samples. The connection and arrangement of “3661” clusters, which define the medium-range order in the system, are enhanced significantly in the sub-T{sub g} annealed sample as compared with the fast cooled glass samples. Unlike some strong binary glass formers such as Cu{sub 64.5}Zr{sub 35.5},more » the clusters representing the short-range order do not form an interconnected interpenetrating network in Al{sub 90}Sm{sub 10,} which has only marginal glass formability.« less

Biocompatibility Study of Zirconium-Based Bulk Metallic Glasses for Orthopedic Applications

NASA Astrophysics Data System (ADS)

He, Wei; Chuang, Andrew; Cao, Zheng; Liaw, Peter K.

2010-07-01

Bulk metallic glasses (BMGs) represent an emerging class of materials that offer an attractive combination of properties, such as high strength, low modulus, good fatigue limit, and near-net-shape formability. The BMGs have been explored in mechanical, chemical, and magnetic applications. However, little research has been attracted in the biomedical field. In this work, we study the potential of BMGs for the orthopedic repair and replacement. We report the biocompatibility study of zirconium (Zr)-based solid BMGs using mouse osteoblast cells. Cell attachment, proliferation, and differentiation are compared to Ti-6Al-4V, a well-studied alloy biomaterial. Our in-vitro study has demonstrated that cells cultured on the Zr-based BMG substrate showed higher attachment, alkaline phosphatase activity, and bone matrix deposition compared to those grown on the control Ti alloy substrate. Cytotoxicity staining also revealed the remarkable viability of cells growing on the BMG substrates.

The effect of tooling design parameters on web-warping in the flexible roll forming of UHSS

NASA Astrophysics Data System (ADS)

Jiao, Jingsi; Rolfe, Bernard; Mendiguren, Joseba; Galdos, Lander; Weiss, Matthias

2013-12-01

To reduce weight and improve passenger safety there is an increased need in the automotive industry to use Ultra High Strength Steels (UHSS) for structural and crash components. However, the application of UHSS is restricted by their limited formability and the difficulty of forming them in conventional processes. An alternative method of manufacturing structural auto body parts from UHSS is the flexible roll forming process which can accommodate materials with high strength and limited ductility in the production of complex and weight-optimised components. However, one major concern in the flexible roll forming is web-warping, which is the height deviation of the profile web area. This paper investigates, using a numerical model, the effect on web-warping with respect to various forming methods. The results demonstrate that different forming methods lead to different amount of web-warping in terms of forming the product with identical geometry.

Gas Forming a V-Shape Aluminum Sheet into a Trough of Saddle-Contour

NASA Astrophysics Data System (ADS)

Lee, Shyong; Lan, Hsien-Chin; Lee, Jye; Wang, Jian-Yih; Huang, J. C.; Chu, Chun Lin

2012-11-01

A sheet metal trough of aluminum alloys is manufactured by gas-forming process at 500 °C. The product with slope walls is of ~1.2 m long and ~260 mm opening width, comprising two conical sinks at two ends. The depth of one sink apex is ~350 mm, which results in the depth/width ratio reaching 1.4. To form such a complex shape with high aspect ratio, a pre-form of V-shape groove is prepared prior to the gas-forming work. When this double concave trough is turned upside down, the convex contour resembles the back of a twin hump camel. The formability of this configuration depends on the gas pressurization rate profile, the working temperature, material's micro-structure, as well as pre-form design. The latter point is demonstrated by comparing two aluminum alloys, AA5182 and SP5083, with nearly same compositions but very different grain sizes.

Hydrogen enhances strength and ductility of an equiatomic high-entropy alloy.

PubMed

Luo, Hong; Li, Zhiming; Raabe, Dierk

2017-08-29

Metals are key materials for modern manufacturing and infrastructures as well as transpot and energy solutions owing to their strength and formability. These properties can severely deteriorate when they contain hydrogen, leading to unpredictable failure, an effect called hydrogen embrittlement. Here we report that hydrogen in an equiatomic CoCrFeMnNi high-entropy alloy (HEA) leads not to catastrophic weakening, but instead increases both, its strength and ductility. While HEAs originally aimed at entropy-driven phase stabilization, hydrogen blending acts opposite as it reduces phase stability. This effect, quantified by the alloy's stacking fault energy, enables nanotwinning which increases the material's work-hardening. These results turn a bane into a boon: hydrogen does not generally act as a harmful impurity, but can be utilized for tuning beneficial hardening mechanisms. This opens new pathways for the design of strong, ductile, and hydrogen tolerant materials.

Mechanical Characterization and Corrosion Testing of X608 Al Alloy

DOE Office of Scientific and Technical Information (OSTI.GOV)

Prabhakaran, Ramprashad; Choi, Jung-Pyung; Stephens, Elizabeth V.

2016-02-07

This paper describes the mechanical characterization and corrosion testing of X608 Al alloy that is being considered for A-pillar covers for heavy-duty truck applications. Recently, PNNL developed a thermo-mechanical process to stamp A-pillar covers at room temperature using this alloy, and the full-size prototype was successfully stamped by a tier-1 supplier. This study was conducted to obtain additional important information related to the newly developed forming process, and to further improve its mechanical properties. The solutionization temperature, pre-strain and paint-bake heat-treatment were found to influence the alloy’s fabricability and mechanical properties. Natural aging effect on the formability was investigated bymore » limiting dome height (LDH) tests. Preliminary corrosion experiments showed that the employed thermo-mechanical treatments did not significantly affect the corrosion behavior of Al X608.« less

The Evolution of In-Grain Misorientation Axes (IGMA) During Deformation of Wrought Magnesium Alloy AZ31

NASA Astrophysics Data System (ADS)

Chun, Y. B.; Davies, C. H. J.

Understanding deformation mechanisms is a prerequisite for the development of more formable magnesium alloys. We have developed a novel approach based on analysis of in-grain misorientation axes which allows identification of the dominant slip system for a large number of grains. We investigated the effects of orientations and temperatures on active deformation mechanisms during the rolling of AZ31, including slip, deformation twinning and deformation banding. The IGMA analysis suggests that increasing rolling temperature promotes activation of prism slip which enhances the rollability of the plate favorably oriented for this slip mode. The approach also reveals an orientation-dependent occurrence of deformation banding and its crystallographic relationship with parent grain. It is concluded that IGMA analysis can be effectively used to study deformation mechanism in hcp metals, and can be used as a criterion for validating some crystal plasticity models.

Designing novel bulk metallic glass composites with a high aluminum content

PubMed Central

Chen, Z. P.; Gao, J. E.; Wu, Y.; Wang, H.; Liu, X. J.; Lu, Z. P.

2013-01-01

The long-standing challenge for forming Al-based BMGs and their matrix composites with a critical size larger than 1 mm have not been answered over the past three decades. In this paper, we reported formation of a series of BMG matrix composites which contain a high Al content up to 55 at.%. These composites can be cast at extraordinarily low cooling rates, compatible with maximum rod diameters of over a centimetre in copper mold casting. Our results indicate that proper additions of transition element Fe which have a positive heat of mixing with the main constituents La and Ce can appreciably improve the formability of the BMG matrix composites by suppressing the precipitation of Al(La,Ce) phase resulted from occurrence of the phase separation. However, the optimum content of Fe addition is strongly dependant on the total amount of the Al content in the Al-(CoCu)-(La,Ce) alloys. PMID:24284800

A coupled thermo-mechanical pseudo inverse approach for preform design in forging

NASA Astrophysics Data System (ADS)

Thomas, Anoop Ebey; Abbes, Boussad; Li, Yu Ming; Abbes, Fazilay; Guo, Ying-Qiao; Duval, Jean-Louis

2017-10-01

Hot forging is a process used to form difficult to form materials as well as to achieve complex geometries. This is possible due to the reduction of yield stress at high temperatures and a subsequent increase in formability. Numerical methods have been used to predict the material yield and the stress/strain states of the final product. Pseudo Inverse Approach (PIA) developed in the context of cold forming provides a quick estimate of the stress and strain fields in the final product for a given initial shape. In this paper, PIA is extended to include the thermal effects on the forging process. A Johnson-Cook thermo-viscoplastic material law is considered and a staggered scheme is employed for the coupling between the mechanical and thermal problems. The results are compared with available commercial codes to show the efficiency and the limitations of PIA.

Texture developed during deformation of Transformation Induced Plasticity (TRIP) steels

NASA Astrophysics Data System (ADS)

Bhargava, M.; Shanta, C.; Asim, T.; Sushil, M.

2015-04-01

Automotive industry is currently focusing on using advanced high strength steels (AHSS) due to its high strength and formability for closure applications. Transformation Induced Plasticity (TRIP) steel is promising material for this application among other AHSS. The present work is focused on the microstructure development during deformation of TRIP steel sheets. To mimic complex strain path condition during forming of automotive body, Limit Dome Height (LDH) tests were conducted and samples were deformed in servo hydraulic press to find the different strain path. FEM Simulations were done to predict different strain path diagrams and compared with experimental results. There is a significant difference between experimental and simulation results as the existing material models are not applicable for TRIP steels. Micro texture studies were performed on the samples using EBSD and X-RD techniques. It was observed that austenite is transformed to martensite and texture developed during deformation had strong impact on limit strain and strain path.

HIGH-RATE FORMABILITY OF HIGH-STRENGTH ALUMINUM ALLOYS: A STUDY ON OBJECTIVITY OF MEASURED STRAIN AND STRAIN RATE

DOE Office of Scientific and Technical Information (OSTI.GOV)

Upadhyay, Piyush; Rohatgi, Aashish; Stephens, Elizabeth V.

2015-02-18

Al alloy AA7075 sheets were deformed at room temperature at strain-rates exceeding 1000 /s using the electrohydraulic forming (EHF) technique. A method that combines high speed imaging and digital image correlation technique, developed at Pacific Northwest National Laboratory, is used to investigate high strain rate deformation behavior of AA7075. For strain-rate sensitive materials, the ability to accurately model their high-rate deformation behavior is dependent upon the ability to accurately quantify the strain-rate that the material is subjected to. This work investigates the objectivity of software-calculated strain and strain rate by varying different parameters within commonly used commercially available digital imagemore » correlation software. Except for very close to the time of crack opening the calculated strain and strain rates are very consistent and independent of the adjustable parameters of the software.« less

Improvement of formability of high strength steel sheets in shrink flanging

NASA Astrophysics Data System (ADS)

Hamedon, Z.; Abe, Y.; Mori, K.

2016-02-01

In the shrinkage flanging, the wrinkling tends to occur due to compressive stress. The wrinkling will cause a difficulty in assembling parts, and severe wrinkling may leads to rupture of parts. The shrinkage flange of the ultra-high strength steel sheets not only defects the product by the occurrence of the wrinkling but also causes seizure and wear of the dies and shortens the life of dies. In the present study, a shape of a punch having gradual contact was optimized in order to prevent the wrinkling in shrinkage flanging of ultra-high strength steel sheets. The sheet was gradually bent from the corner of the sheet to reduce the compressive stress. The wrinkling in the shrink flanging of the ultra-high strength steel sheets was prevented by the punch having gradual contact. It was found that the punch having gradual contact is effective in preventing the occurrence of wrinkling in the shrinkage flanging.

Designing novel bulk metallic glass composites with a high aluminum content.

PubMed

Chen, Z P; Gao, J E; Wu, Y; Wang, H; Liu, X J; Lu, Z P

2013-11-27

The long-standing challenge for forming Al-based BMGs and their matrix composites with a critical size larger than 1 mm have not been answered over the past three decades. In this paper, we reported formation of a series of BMG matrix composites which contain a high Al content up to 55 at.%. These composites can be cast at extraordinarily low cooling rates, compatible with maximum rod diameters of over a centimetre in copper mold casting. Our results indicate that proper additions of transition element Fe which have a positive heat of mixing with the main constituents La and Ce can appreciably improve the formability of the BMG matrix composites by suppressing the precipitation of Al(La,Ce) phase resulted from occurrence of the phase separation. However, the optimum content of Fe addition is strongly dependant on the total amount of the Al content in the Al-(CoCu)-(La,Ce) alloys.

Polymer-Ceramic Composite Materials for Pyroelectric Infrared Detectors: An Overview

NASA Technical Reports Server (NTRS)

Aggarwal, M. D; Currie, J. R.; Penn, B. G.; Batra, A. K.; Lal, R. B.

2007-01-01

Ferroelectrics:Polymer composites can be considered an established substitute for conventional electroceramics and ferroelectric polymers. The composites have a unique blend of polymeric properties such as mechanical flexibility, high strength, formability, and low cost, with the high electro-active properties of ceramic materials. They have attracted considerable interest because of their potential use in pyroelectric infrared detecting devices and piezoelectric transducers. These flexible sensors and transducers may eventually be useful for their health monitoring applications for NASA crew launch vehicles and crew exploration vehicles being developed. In the light of many technologically important applications in this field, it is worthwhile to present an overview of the pyroelectric infrared detector theory, models to predict dielectric behavior and pyroelectric coefficient, and the concept of connectivity and fabrication techniques of biphasic composites. An elaborate review of Pyroelectric-Polymer composite materials investigated to date for their potential use in pyroelectric infrared detectors is presented.

Electrically Conductive and Protective Coating for Planar SOFC Stacks

DOE Office of Scientific and Technical Information (OSTI.GOV)

Choi, Jung-Pyung; Stevenson, Jeffry W.

Ferritic stainless steels are preferred interconnect materials for intermediate temperature SOFCs because of their resistance to oxidation, high formability and low cost. However, their protective oxide layer produces Cr-containing volatile species at SOFC operating temperatures and conditions, which can cause cathode poisoning. Electrically conducting spinel coatings have been developed to prevent cathode poisoning and to maintain an electrically conductive pathway through SOFC stacks. However, this coating is not compatible with the formation of stable, hermetic seals between the interconnect frame component and the ceramic cell. Thus, a new aluminizing process has been developed by PNNL to enable durable sealing, preventmore » Cr evaporation, and maintain electrical insulation between stack repeat units. Hence, two different types of coating need to have stable operation of SOFC stacks. This paper will focus on the electrically conductive coating process. Moreover, an advanced coating process, compatible with a non-electrically conductive coating will be« less

Recovery behaviour of shape memory polyurethane based laminates after thermoforming

NASA Astrophysics Data System (ADS)

Wu, Shuiliang; Xu, Wensen; Prasath Balamurugan, G.; Thompson, Michael R.; Nielsen, Kent E.; Brandys, Frank A.

2017-11-01

Shape memory polymers (SMPs) can be used to produce a new class of decorative films capable of improved formability and shape recovery in polymer laminates, which are increasingly being used for automotive, aerospace, construction and commercial applications. As a relatively new field there is little knowledge on the shape recovery behaviour of laminates with a SMP film and few methods of quantify that behaviour. The influences of different variables that affect the recovery behaviour of thermoplastic shape memory polyurethanes based laminates including ambient temperature (45 °C and 65 °C), material modulus, and adhesive strength were investigated after thermoforming, through both experimental and modelling methods. The empirical model assisted in identifying the contributions of the adhesive to transfer stresses, which dampened the recovery of the laminate with lower shear strength adhesives. Increasing ambient temperature and the film modulus increased both the final angle recovery ratios and recovery rates.

Energy efficient engine shroudless, hollow fan blade technology report

NASA Technical Reports Server (NTRS)

Michael, C. J.

1981-01-01

The Shroudless, Hollow Fan Blade Technology program was structured to support the design, fabrication, and subsequent evaluation of advanced hollow and shroudless blades for the Energy Efficient Engine fan component. Rockwell International was initially selected to produce hollow airfoil specimens employing the superplastic forming/diffusion bonding (SPF/DB) fabrication technique. Rockwell demonstrated that a titanium hollow structure could be fabricated utilizing SPF/DB manufacturing methods. However, some problems such as sharp internal cavity radii and unsatisfactory secondary bonding of the edge and root details prevented production of the required quantity of fatigue test specimens. Subsequently, TRW was selected to (1) produce hollow airfoil test specimens utilizing a laminate-core/hot isostatic press/diffusion bond approach, and (2) manufacture full-size hollow prototype fan blades utilizing the technology that evolved from the specimen fabrication effort. TRW established elements of blade design and defined laminate-core/hot isostatic press/diffusion bonding fabrication techniques to produce test specimens. This fabrication technology was utilized to produce full size hollow fan blades in which the HIP'ed parts were cambered/twisted/isothermally forged, finish machined, and delivered to Pratt & Whitney Aircraft and NASA for further evaluation.

Multifunctional Beta Ti Alloy with Improved Specific Strength

NASA Astrophysics Data System (ADS)

Park, Chan Hee; Hong, Jae-Keun; Lee, Sang Won; Yeom, Jong-Taek

2017-12-01

Gum metals feature properties such as ultrahigh strength, ultralow elastic modulus, superelasticity, and superplasticity. They are composed of elements from Groups 4 and 5 of the periodic table and exist when the valance electron concentration (\\overline{e/a}) is 4.24; the bond order (\\overline{Bo}) is 2.87; and the "d" electron-orbital energy level (\\overline{Md}) is 2.45 eV. Typical compositions include Ti-23Nb-2Zr-0.7Ta-O and Ti-12Ta-9Nb-6Zr-3 V-O, which contain large amounts of heavy Group-5 elements such as Nb and Ta. In the present study, to improve the specific strength of a multifunctional beta Ti alloy, three alloys (Ti-20Nb-5Zr-1Fe-O, Ti-12Zr-10Mo-4Nb-O, and Ti-24Zr-9Cr-3Mo-O) were designed by satisfying the above three requirements while adding Fe, Mo, and Cr, which are not only lightweight but also have strong hardening effects. Microstructural and mechanical property analyses revealed that Ti-20Nb-5Zr-1Fe-O has a 25% higher specific strength than gum metal while maintaining an ultralow elastic modulus.

Hot deformation behavior of uniform fine-grained GH4720Li alloy based on its processing map

NASA Astrophysics Data System (ADS)

Yu, Qiu-ying; Yao, Zhi-hao; Dong, Jian-xin

2016-01-01

The hot deformation behavior of uniform fine-grained GH4720Li alloy was studied in the temperature range from 1040 to 1130°C and the strain-rate range from 0.005 to 0.5 s-1 using hot compression testing. Processing maps were constructed on the basis of compression data and a dynamic materials model. Considerable flow softening associated with superplasticity was observed at strain rates of 0.01 s-1 or lower. According to the processing map and observations of the microstructure, the uniform fine-grained microstructure remains intact at 1100°C or lower because of easily activated dynamic recrystallization (DRX), whereas obvious grain growth is observed at 1130°C. Metallurgical instabilities in the form of non-uniform microstructures under higher and lower Zener-Hollomon parameters are induced by local plastic flow and primary γ' local faster dissolution, respectively. The optimum processing conditions at all of the investigated strains are proposed as 1090-1130°C with 0.08-0.5 s-1 and 0.005-0.008 s-1 and 1040-1085°C with 0.005-0.06 s-1.

Thermal analysis of 3-mol%-yttria-stabilized tetragonal zirconia powder doped with copper oxide

DOE Office of Scientific and Technical Information (OSTI.GOV)

Seidensticker, J.R.; Mayo, M.J.

Thermal analysis was performed upon 3-mol%-yttria-stabilized tetragonal zirconia polycrystals (3Y-TZP) which had been doped with CuO using an aqueous adsorption technique. Cyclic differential thermal analysis (DTA) scans indicated that the CuO present on the powder surfaces first transforms to Cu{sub 2}O and then melts. The molten Cu{sub 2}O then reacts with yttria at the powder surfaces to form a new phase containing Y, Cu, and O. Because Y takes time to diffuse to the particle surfaces, the apparent melting point of this new phase appears at higher temperatures in initial DTA scans than in subsequent scans. Vaporization of the moltenmore » copper-oxide-rich phase at the temperatures studied causes a gradual shift in composition from Y{sub 2}Cu{sub 4}O{sub 5} to the less copper-rich Y{sub 2}Cu{sub 2}O{sub 5} phase. The presence of the Y{sub 2}Cu{sub 2}O{sub 5} phase in CuO-doped 3Y-TZP allows for previous sintering and superplasticity results to be explained.« less

Development of dispersion-strengthened Ni-Cr-ThOz alloys for the space shuttle thermal protection system

NASA Technical Reports Server (NTRS)

Blankenship, C. P.; Saunders, N. T.

1972-01-01

Manufacturing processes were developed for TD-NiCr providing small sheet (45 x 90 cm), and larger sheet (60 x 150 cm) and foil. The alternate alloy, DS-NiCr, was produced by pack-chromizing Ni-ThO2 sheet. Formability criteria are being established for basic sheet forming processes, which are brake forming, corrugation forming, joggling, dimpling, and beading. Resistance spot welding (fusion and solid state), resistance seam welding, solid state diffusion welding, and brazing are included in the joining programs. Major emphasis is centered on an Al-modified Ni-Cr-ThO2 alloy development. These alloys, containing 3 to 5% Al, form the protective Al2O3 scale. This enhances oxidation resistance under reentry conditions. Both TD-NiCrAl and DS-NiCrAl alloys are included. A tentative composition of Ni-16Cr-3.5Al-2ThO2 was selected based on oxidation resistance and fabricability.

Optimized cutting and forming parameters for a robust collar drawing process for hot-rolled complex-phase steels

NASA Astrophysics Data System (ADS)

Kovacs, S.; Beier, T.; Woestmann, S.

2017-09-01

The demands on materials for automotive applications are steadily increasing. For chassis components, the trend is towards thinner and higher strength materials for weight and cost reduction. In view of attainable strengths of up to 1200 MPa for hot rolled materials, certain aspects need to be analysed and evaluated in advance in the development process using these materials. Collars in particular, for example in control arms, have been in focus for part and process design. Issues concerning edge and surface cracks are observed due to improper geometry and process layout. The hole expansion capability of the chosen material grade has direct influence on the achievable collar height. In general, shear cutting reduces the residual formability of blank edges and the hole expansion capability. In this paper, using the example of the complex phase steel CP-W® 800 of thyssenkrupp, it is shown how a suitable geometry of a collar and optimum shear cutting parameters can be chosen.

Optimization of Process Parameters for High Efficiency Laser Forming of Advanced High Strength Steels within Metallurgical Constraints

NASA Astrophysics Data System (ADS)

Sheikholeslami, Ghazal; Griffiths, Jonathan; Dearden, Geoff; Edwardson, Stuart P.

Laser forming (LF) has been shown to be a viable alternative to form automotive grade advanced high strength steels (AHSS). Due to their high strength, heat sensitivity and low conventional formability show early fractures, larger springback, batch-to-batch inconsistency and high tool wear. In this paper, optimisation of the LF process parameters has been conducted to further understand the impact of a surface heat treatment on DP1000. A FE numerical simulation has been developed to analyse the dynamic thermo-mechanical effects. This has been verified against empirical data. The goal of the optimisation has been to develop a usable process window for the LF of AHSS within strict metallurgical constraints. Results indicate it is possible to LF this material, however a complex relationship has been found between the generation and maintenance of hardness values in the heated zone. A laser surface hardening effect has been observed that could be beneficial to the efficiency of the process.

Glass formability in medium-sized molecular systems/pharmaceuticals. I. Thermodynamics vs. kinetics.

PubMed

Tu, Wenkang; Li, Xiangqian; Chen, Zeming; Liu, Ying Dan; Labardi, Massimiliano; Capaccioli, Simone; Paluch, M; Wang, Li-Min

2016-05-07

Scrutinizing critical thermodynamic and kinetic factors for glass formation and the glass stability of materials would benefit the screening of the glass formers for the industry of glassy materials. The present work aims at elucidating the factors that contribute to the glass formation by investigating medium-sized molecules of pharmaceuticals. Glass transition related thermodynamics and kinetics are performed on the pharmaceuticals using calorimetric, dielectric, and viscosity measurements. The characteristic thermodynamic and kinetic parameters of glass transition are found to reproduce the relations established for small-molecule glass formers. The systematic comparison of the thermodynamic and kinetic contributions to glass formation reveals that the melting-point viscosity is the crucial quantity for the glass formation. Of more interest is the finding of a rough correlation between the melting-point viscosity and the entropy of fusion normalized by the number of beads of the pharmaceuticals, suggesting the thermodynamics can partly manifest its contribution to glass formation via kinetics.

Glass formability in medium-sized molecular systems/pharmaceuticals. I. Thermodynamics vs. kinetics

DOE Office of Scientific and Technical Information (OSTI.GOV)

Tu, Wenkang; Li, Xiangqian; Chen, Zeming

Scrutinizing critical thermodynamic and kinetic factors for glass formation and the glass stability of materials would benefit the screening of the glass formers for the industry of glassy materials. The present work aims at elucidating the factors that contribute to the glass formation by investigating medium-sized molecules of pharmaceuticals. Glass transition related thermodynamics and kinetics are performed on the pharmaceuticals using calorimetric, dielectric, and viscosity measurements. The characteristic thermodynamic and kinetic parameters of glass transition are found to reproduce the relations established for small-molecule glass formers. The systematic comparison of the thermodynamic and kinetic contributions to glass formation reveals thatmore » the melting-point viscosity is the crucial quantity for the glass formation. Of more interest is the finding of a rough correlation between the melting-point viscosity and the entropy of fusion normalized by the number of beads of the pharmaceuticals, suggesting the thermodynamics can partly manifest its contribution to glass formation via kinetics.« less

Microstructure evolution and texture development of hot form-quench (HFQ) AZ31 twin roll cast (TRC) magnesium alloy

NASA Astrophysics Data System (ADS)

Alias, J.; Zhou, X.; Das, Sanjeev; El-Fakir, Omer; Thompson, G. E.

2017-12-01

The present study on the microstructure evolution of hot form-quench (HFQ) AZ31 twin roll cast magnesium alloy attempt to provide an understanding on the grain structure and heterogeneous intermetallic phase formation in the alloy and texture development following the HFQ process. Grain recrystallization and partial dissolution of eutectic β-Mg17Al12 phase particles were occurred during the solution heat treatment at 450°C, leaving the alloy consists of recrystallized grains and discontinuous or random β-Mg17Al12 phase particles distribution with small volume fraction. The particles act as effective nucleation sites for new grains during recrystallization and variation of recrystallization occurrence contributed to texture alteration. The partial or full β-Mg17Al12 phase dissolution following the HFQ induces void formation that act as fracture nucleation site and the corresponding texture alteration in the recrystallized grains led to poor formability in TRC alloy.

The effect of tooling design parameters on web-warping in the flexible roll forming of UHSS

DOE Office of Scientific and Technical Information (OSTI.GOV)

Jiao, Jingsi; Weiss, Matthias; Rolfe, Bernard

To reduce weight and improve passenger safety there is an increased need in the automotive industry to use Ultra High Strength Steels (UHSS) for structural and crash components. However, the application of UHSS is restricted by their limited formability and the difficulty of forming them in conventional processes. An alternative method of manufacturing structural auto body parts from UHSS is the flexible roll forming process which can accommodate materials with high strength and limited ductility in the production of complex and weight-optimised components. However, one major concern in the flexible roll forming is web-warping, which is the height deviation ofmore » the profile web area. This paper investigates, using a numerical model, the effect on web-warping with respect to various forming methods. The results demonstrate that different forming methods lead to different amount of web-warping in terms of forming the product with identical geometry.« less

Forming Limit Diagram of Titanium and Stainless Steel Alloys to Study the Formability of Hydro-Mechanical Deep Drawing Parts

NASA Astrophysics Data System (ADS)

Shirizly, A.

2005-08-01

The increase demand for stronger, lighter and economic sheet metal products, make the Hydromecanical deep drawing process lately more and more popular. The Hydromecanical process is used in almost all types of sheet metal parts from home appliances and kitchenware to automotive and aviation industries. Therefore, many common materials were tested and characterized by their ability to sustain large strains via the well known Forming Limit Diagram (FLD). The aim of this work is to examine the forming capability if the Hydromecanical process in production of hemisphere parts made of materials commonly used in the aviation and aerospace industries. Experimental procedures were carried out to assess their ductility through FLD and the Forming Limit Carve (FLC).Two type of material sheets were tested herewith for demonstrating the procedure: commercial pure titanium and stainless steel 316L. A numerical simulation of the Hydromecanical process was examined and compared to self made Hydromecanical deep drawing of hemispherical parts.

Reduction of liquid metal embrittlement in copper-brazed stainless steel joints

NASA Astrophysics Data System (ADS)

Uhlig, T.; Fedorov, V.; Elßner, M.; Wagner, G.; Weis, S.

2017-03-01

Due to its very good formability and the low raw material cost, pure copper in form of foils is commonly used to braze plate heat exchangers made of stainless steel. The difference in the electrochemical potentials of brazing filler and base material leads to corrosion effects in contact with electrolytes. This may lead to leakages, which decrease the reliability of the heat exchanger during service in potable water. The dissolution of the emerging corrosion products of brazing filler and base material induces the migration of heavy metal ions, such as Cu2+ and Ni2+, into the potable water. The so-called liquid metal embrittlement, which takes place during the brazing process, may intensify the corrosion. The brazing filler infiltrates the stainless steel along the grain boundaries and causes an embrittlement. This paper deals with the determination of the grain boundary erosion dependent on the degree of deformation and heat treatment of the stainless steel AISI 316L.

Non-Heat Treatable Alloy Sheet Products

DOE Office of Scientific and Technical Information (OSTI.GOV)

Hayden, H.W.; Barthold, G.W.; Das, S.K.

ALCAR is an innovative approach for conducting multi-company, pre-competitive research and development programs. ALCAR has been formed to crate a partnership of aluminum producers, the American Society of Mechanical Engineers Center for Research and Technology Development (ASME/CRTD), the United States Department of Energy (USDOE), three USDOE National Laboratories, and a Technical Advisory Committee for conducting cooperative, pre-competitive research on the development of flower-cost, non-heat treated (NHT) aluminum alloys for automotive sheet applications with strength, formability and surface appearance similar to current heat treated (HT) aluminum alloys under consideration. The effort has been supported by the USDOE, Office of Transportation Technologymore » (OTT) through a three-year program with 50/50 cost share at a total program cost of $3 million. The program has led to the development of new and modified 5000 series aluminum ally compositions. Pilot production-size ingots have bee n melted, cast, hot rolled and cold rolled. Stamping trials on samples of rolled product for demonstrating production of typical automotive components have been successful.« less

Overcoming the Time Limitation in Molecular Dynamics Simulation of Crystal Nucleation: A Persistent-Embryo Approach

DOE Office of Scientific and Technical Information (OSTI.GOV)

Sun, Yang; Song, Huajing; Zhang, Feng

The crystal nucleation from liquid in most cases is too rare to be accessed within the limited time scales of the conventional molecular dynamics (MD) simulation. Here, we developed a “persistent embryo” method to facilitate crystal nucleation in MD simulations by preventing small crystal embryos from melting using external spring forces. We applied this method to the pure Ni case for a moderate undercooling where no nucleation can be observed in the conventional MD simulation, and obtained nucleation rate in good agreement with the experimental data. Moreover, the method is applied to simulate an even more sluggish event: the nucleationmore » of the B2 phase in a strong glass-forming Cu-Zr alloy. The nucleation rate was found to be 8 orders of magnitude smaller than Ni at the same undercooling, which well explains the good glass formability of the alloy. In conclusion, our work opens a new avenue to study solidification under realistic experimental conditions via atomistic computer simulation.« less

Ultrastrong ductile and stable high-entropy alloys at small scales.

PubMed

Zou, Yu; Ma, Huan; Spolenak, Ralph

2015-07-10

Refractory high-entropy alloys (HEAs) are a class of emerging multi-component alloys, showing superior mechanical properties at elevated temperatures and being technologically interesting. However, they are generally brittle at room temperature, fail by cracking at low compressive strains and suffer from limited formability. Here we report a strategy for the fabrication of refractory HEA thin films and small-sized pillars that consist of strongly textured, columnar and nanometre-sized grains. Such HEA pillars exhibit extraordinarily high yield strengths of ∼ 10 GPa--among the highest reported strengths in micro-/nano-pillar compression and one order of magnitude higher than that of its bulk form--and their ductility is considerably improved (compressive plastic strains over 30%). Additionally, we demonstrate that such HEA films show substantially enhanced stability for high-temperature, long-duration conditions (at 1,100 °C for 3 days). Small-scale HEAs combining these properties represent a new class of materials in small-dimension devices potentially for high-stress and high-temperature applications.

Research on Al-alloy sheet forming formability during warm/hot sheet hydroforming based on elliptical warm bulging test

NASA Astrophysics Data System (ADS)

Cai, Gaoshen; Wu, Chuanyu; Gao, Zepu; Lang, Lihui; Alexandrov, Sergei

2018-05-01

An elliptical warm/hot sheet bulging test under different temperatures and pressure rates was carried out to predict Al-alloy sheet forming limit during warm/hot sheet hydroforming. Using relevant formulas of ultimate strain to calculate and dispose experimental data, forming limit curves (FLCS) in tension-tension state of strain (TTSS) area are obtained. Combining with the basic experimental data obtained by uniaxial tensile test under the equivalent condition with bulging test, complete forming limit diagrams (FLDS) of Al-alloy are established. Using a quadratic polynomial curve fitting method, material constants of fitting function are calculated and a prediction model equation for sheet metal forming limit is established, by which the corresponding forming limit curves in TTSS area can be obtained. The bulging test and fitting results indicated that the sheet metal FLCS obtained were very accurate. Also, the model equation can be used to instruct warm/hot sheet bulging test.

Formability and macroscopic shearing of a titanium alloy Ti-6Al-4V under channel die compression

NASA Astrophysics Data System (ADS)

Francillette, Henri; Garand, Christian

2017-10-01

The mechanical behavior of Ti-6Al-4V is analyzed using channel die compression tests at room temperature. Specimens were cut out from a starting sheet in order to consider samples with specific initial crystallographic textures. Three types of specimens are considered in the study using an angle θ defined with the initial directions LD0, TD0 and ND0 of the starting sheet. The following values of θ are considered : 0°, 45° and 90°. Plastic deformations up to 20% are considered. Several experimental techniques are used, namely optical microscopy, SEM and Xray diffraction for texture evolution. The true stress-strain curves are plotted and the shape change of the specimens is analyzed. A macroscopic shearing is observed for one the three types of initial textures considered, notably θ = 45°. To complete the study, the Taylor model is applied in order to compare the activation of the mechanisms of the α phase in the different specimens.

Overcoming the Time Limitation in Molecular Dynamics Simulation of Crystal Nucleation: A Persistent-Embryo Approach

DOE PAGES

Sun, Yang; Song, Huajing; Zhang, Feng; ...

2018-02-23

The crystal nucleation from liquid in most cases is too rare to be accessed within the limited time scales of the conventional molecular dynamics (MD) simulation. Here, we developed a “persistent embryo” method to facilitate crystal nucleation in MD simulations by preventing small crystal embryos from melting using external spring forces. We applied this method to the pure Ni case for a moderate undercooling where no nucleation can be observed in the conventional MD simulation, and obtained nucleation rate in good agreement with the experimental data. Moreover, the method is applied to simulate an even more sluggish event: the nucleationmore » of the B2 phase in a strong glass-forming Cu-Zr alloy. The nucleation rate was found to be 8 orders of magnitude smaller than Ni at the same undercooling, which well explains the good glass formability of the alloy. In conclusion, our work opens a new avenue to study solidification under realistic experimental conditions via atomistic computer simulation.« less

Effect of differential speed rolling on the texture evolution of Mg-4Zn-1Gd alloy

NASA Astrophysics Data System (ADS)

Shim, Myeong-Shik; Suh, Byeong-Chan; Kim, Jae H.; Kim, Nack J.

2015-05-01

The microstructural and texture evolution during differential speed rolling process of Mg 4Zn-1Gd (wt%) alloy have been investigated by means of electron backscatter diffraction observation and texture analysis. The angular distribution of basal poles are inclined about 10° from the normal direction towards the rolling direction and the maximum intensities of basal poles are decreased, compared to the conventional rolling process. Such an inclination of angular distribution of basal poles can be induced by the operation of shear stress along the rolling direction, as much as one quarter of tensile stress along the RD and one quarter of compressive stress along the ND. When the reduction ratios in differential speed rolling increase, there is no difference in texture evolution although there is a significant change in activated twinning systems. In addition, the engineering stresses after differential speed rolling are also similar to that after conventional rolling process, while ductility and stretch formability in the former are worse than those in the latter.

The effects of strain and stress state in hot forming of mg AZ31 sheet

NASA Astrophysics Data System (ADS)

Sherek, Paul A.; Carpenter, Alexander J.; Hector, Louis G.; Krajewski, Paul E.; Carter, Jon T.; Lasceski, Joshua; Taleff, Eric M.

Wrought magnesium alloys, such as AZ31 sheet, are of considerable interest for light-weighting of vehicle structural components. The poor room-temperature ductility of AZ31 sheet has been a hindrance to forming the complex part shapes necessary for practical applications. However, the outstanding formability of AZ31 sheet at elevated temperature provides an opportunity to overcome that problem. Complex demonstration components have already been produced at 450°C using gas-pressure forming. Accurate simulations of such hot, gas-pressure forming will be required for the design and optimization exercises necessary if this technology is to be implemented commercially. We report on experiments and simulations used to construct the accurate material constitutive models necessary for finite-element-method simulations. In particular, the effects of strain and stress state on plastic deformation of AZ31 sheet at 450°C are considered in material constitutive model development. Material models are validated against data from simple forming experiments.

A parametric study of surface roughness and bonding mechanisms of aluminum alloys with epoxies: a molecular dynamics simulation

NASA Astrophysics Data System (ADS)

Timilsina, Rajendra; Termaath, Stephanie

The marine environment is highly aggressive towards most materials. However, aluminium-magnesium alloys (Al-Mg, specifically, 5xxx series) have exceptionally long service life in such aggressive marine environments. For instance, an Al-Mg alloy, AA5083, is extensively used in naval structures because of its good mechanical strength, formability, seawater corrosion resistance and weldability. However, bonding mechanisms of these alloys with epoxies in a rough surface environment are not fully understood yet. It requires a rigorous investigation at molecular or atomic levels. We performed a molecular dynamics simulation to study an adherend surface preparation and surface bonding mechanisms of Al-Mg alloy (AA5083) with different epoxies by developing several computer models. Various distributions of surface roughness are introduced in the models and performed molecular dynamics simulations. Formation of a beta phase (Al3Mg2) , microstructures, bonding energies at the interface, bonding strengths and durability are investigated. Office of Naval Research.

A Study on Segmented Multiple-Step Forming of Doubly Curved Thick Plate by Reconfigurable Multi-Punch Dies

DOE Office of Scientific and Technical Information (OSTI.GOV)

Ko, Young Ho; Han, Myoung Soo; Han, Jong Man

2007-05-17

Doubly curved thick plate forming in shipbuilding industries is currently performed by a thermal forming process, called as Line Heating by using gas flame torches. Due to the empirical manual work of it, the industries are eager for an alternative way to manufacture curved thick plates for ships. It was envisaged in this study to manufacture doubly curved thick plates by the multi-punch die forming. Experiments and finite element analyses were conducted to evaluate the feasibility of the reconfigurable discrete die forming to the thick plates. Single and segmented multiple step forming procedures were considered from both forming efficiency andmore » accuracy. Configuration of the multi-punch dies suitable for the segmented multiple step forming was also explored. As a result, Segmented multiple step forming with matched dies had a limited formability when the objective shapes become complicate, while a unmatched die configuration provided better possibility to manufacture large curved plates for ships.« less

Analysis of properties laser welded RAK 40/70 steel sheets

NASA Astrophysics Data System (ADS)

Evin, E.; Tomáš, M.; Fujda, M.

2017-11-01

Both, the ecological production and operation of vehicles demand using such materials for deformation zones’ structural parts, which show some specific properties and use innovative technologies to process them. Specific requirements for functionality (strength, stiffness, deformation work, fatigue properties) are closely linked to processability (formability). In the paper are presented results for multiphase TRIP steel RAK40/70 when welded by pulse solid-state fiber laser YLS-5000. Based on microstructure analysis in the fusion zone and heat affected zone the welding parameters were optimised. The influence of laser welding on the strength and deformation properties was verified by characteristics of strength, stiffness and deformation work, as they were calculated from mechanical properties measured by tensile test and three-point bending test. The knowledge gathered in the field of laser welding influence on the strength and deformation properties of multiphase TRIP steel RAK40/70 should help designers when design the lightweight structural parts of the car body.

Overcoming the Time Limitation in Molecular Dynamics Simulation of Crystal Nucleation: A Persistent-Embryo Approach

NASA Astrophysics Data System (ADS)

Sun, Yang; Song, Huajing; Zhang, Feng; Yang, Lin; Ye, Zhuo; Mendelev, Mikhail I.; Wang, Cai-Zhuang; Ho, Kai-Ming

2018-02-01

The crystal nucleation from liquid in most cases is too rare to be accessed within the limited time scales of the conventional molecular dynamics (MD) simulation. Here, we developed a "persistent embryo" method to facilitate crystal nucleation in MD simulations by preventing small crystal embryos from melting using external spring forces. We applied this method to the pure Ni case for a moderate undercooling where no nucleation can be observed in the conventional MD simulation, and obtained nucleation rate in good agreement with the experimental data. Moreover, the method is applied to simulate an even more sluggish event: the nucleation of the B 2 phase in a strong glass-forming Cu-Zr alloy. The nucleation rate was found to be 8 orders of magnitude smaller than Ni at the same undercooling, which well explains the good glass formability of the alloy. Thus, our work opens a new avenue to study solidification under realistic experimental conditions via atomistic computer simulation.

Prediction of hole expansion ratio for various steel sheets based on uniaxial tensile properties

NASA Astrophysics Data System (ADS)

Kim, Jae Hyung; Kwon, Young Jin; Lee, Taekyung; Lee, Kee-Ahn; Kim, Hyoung Seop; Lee, Chong Soo

2018-01-01

Stretch-flangeability is one of important formability parameters of thin steel sheets used in the automotive industry. There have been many attempts to predict hole expansion ratio (HER), a typical term to evaluate stretch-flangeability, using uniaxial tensile properties for convenience. This paper suggests a new approach that uses total elongation and average normal anisotropy to predict HER of thin steel sheets. The method provides a good linear relationship between HER of the machined hole and the predictive variables in a variety of materials with different microstructures obtained using different processing methods. The HER of the punched hole was also well predicted using the similar approach, which reflected only the portion of post uniform elongation. The physical meaning drawn by our approach successfully explained the poor HER of austenitic steels despite their considerable elongation. The proposed method to predict HER is simple and cost-effective, so it will be useful in industry. In addition, the model provides a physical explanation of HER, so it will be useful in academia.

The influence of heat treatment on properties of cold rolled alloyed steel and nickel superalloys sheets used in aircraft industry

NASA Astrophysics Data System (ADS)

Zaba, K.; Dul, I.; Puchlerska, S.

2017-02-01

Superalloys based on nickel and selected steels are widely used in the aerospace industry, because of their excellent mechanical properties, heat resistance and creep resistance. Metal sheets of these materials are plastically deformed and applied, inter alia, to critical components of aircraft engines. Due to their chemical composition these materials are hardly deformable. There are various methods to improve the formability of these materials, including plastic deformation at an elevated or high temperature, or a suitable heat treatment before forming process. The paper presents results of the metal sheets testing after heat treatment. For the research, sheets of two types of nickel superalloys type Inconel and of three types of steel were chosen. The materials were subjected to multivariate heat treatment at different temperature range and time. After this step, mechanical properties were examined according to the metal sheet rolling direction. The results were compared and the optimal type of pre-trial softening heat treatment for each of the materials was determined.

Weldability of AA 5052 H32 aluminium alloy by TIG welding and FSW process - A comparative study

NASA Astrophysics Data System (ADS)

Shanavas, S.; Raja Dhas, J. Edwin

2017-10-01

Aluminium 5xxx series alloys are the strongest non-heat treatable aluminium alloy. Its application found in automotive components and body structures due to its good formability, good strength, high corrosion resistance, and weight savings. In the present work, the influence of Tungsten Inert Gas (TIG) welding parameters on the quality of weld on AA 5052 H32 aluminium alloy plates were analyzed and the mechanical characterization of the joint so produced was compared with Friction stir (FS) welded joint. The selected input variable parameters are welding current and inert gas flow rate. Other parameters such as welding speed and arc voltage were kept constant throughout the study, based on the response from several trial runs conducted. The quality of the weld is measured in terms of ultimate tensile strength. A double side V-butt joints were fabricated by double pass on one side to ensure maximum strength of TIG welded joints. Macro and microstructural examination were conducted for both welding process.

Deformation-Induced Recrystallization of Magnesium Single Crystals at Ambient Temperature

NASA Astrophysics Data System (ADS)

Molodov, K. D.; Al-Samman, T.; Molodov, D. A.

2015-04-01

Specially oriented magnesium single crystals were subjected to plane strain compression along the <112¯0> direction in c-axis extension at ambient temperature. The samples exhibited outstanding formability deforming up to a logarithmic final strain of -1. Investigations by optical and orientation imaging microscopy revealed that massive {101¯2} extension twinning at low strains consumed the whole sample and resulted in new soft orientations for slip. Observations also indicated that additional twinning took place in the completely twinned matrix by secondary and tertiary twinning events. At advanced stages of deformation newly formed, equiaxed small grains were observed within numerous bands related to former deformation twins. These “recrystallized” grains characterized by a low grain orientation spread of less than 1° generated new orientations, which led to a substantial weakening and randomization of the texture during deformation up to very large strains. The reported results in this paper are discussed with regard to the microstructure evolution arising from multiple twinning and continuous dynamic recrystallization at room temperature.

Overcoming the Time Limitation in Molecular Dynamics Simulation of Crystal Nucleation: A Persistent-Embryo Approach.

PubMed

Sun, Yang; Song, Huajing; Zhang, Feng; Yang, Lin; Ye, Zhuo; Mendelev, Mikhail I; Wang, Cai-Zhuang; Ho, Kai-Ming

2018-02-23

The crystal nucleation from liquid in most cases is too rare to be accessed within the limited time scales of the conventional molecular dynamics (MD) simulation. Here, we developed a "persistent embryo" method to facilitate crystal nucleation in MD simulations by preventing small crystal embryos from melting using external spring forces. We applied this method to the pure Ni case for a moderate undercooling where no nucleation can be observed in the conventional MD simulation, and obtained nucleation rate in good agreement with the experimental data. Moreover, the method is applied to simulate an even more sluggish event: the nucleation of the B2 phase in a strong glass-forming Cu-Zr alloy. The nucleation rate was found to be 8 orders of magnitude smaller than Ni at the same undercooling, which well explains the good glass formability of the alloy. Thus, our work opens a new avenue to study solidification under realistic experimental conditions via atomistic computer simulation.

Gas Release Behavior of Cu-TiH2 Composite Powder and Its Application as a Blowing Agent to Fabricate Aluminum Foams with Low Porosity and Small Pore Size

NASA Astrophysics Data System (ADS)

Cheng, Ying; Li, Yanxiang; Chen, Xiang; Liu, Zhiyong; Zhou, Xu; Wang, Ningzhen

2018-06-01

Compared to traditional pore structure with high porosity (≥ 80 pct) and large pore size (≥ 3 mm), aluminum foams with low porosity (60 to 70 pct) and small pore size (≤ 2 mm) possess higher compressive property and formability. In order to achieve the goal of reducing pore size, Cu-TiH2 composite powder prepared by ball milling preoxidized TiH2 with Cu powder was used as a blowing agent. Its gas release behavior was characterized by thermogravimetric analysis and differential scanning calorimetry. The results show that the ball milling treatment can advance the gas release process and slow the gas release rate at the same time. All these changes are favorable to the reduction of porosity and pore size. Such Cu-TiH2 composite powder provides an alternative way to fabricate aluminum foams with low porosity and small pore size.

Microstructure Characterization of Weakly Textured and Fine Grained AZ61 Sheet

NASA Astrophysics Data System (ADS)

Berman, T. D.; Donlon, W.; Hung, C. K.; Milligan, P.; Decker, R.; Pollock, T. M.; Jones, J. W.

Formability in magnesium alloy sheet is strongly limited by a strong basal texture in the as-rolled material, which is difficulty to remove by thermal processing. We introduce a new process to the control of texture by combining Thixomolding and Thermomechanical Processing (TTMP). Plates of AZ61L with a divorced β-Mg17Al12 eutectic are produced by Thixomolding, resulting in a non-textured, fine grained (2.8 µm) precursor. Sheet produced from the plate by single pass warm-rolling exhibits a weaker texture, and more isotropic tensile deformation than generally observed in AZ-series alloy sheet. Recrystallization annealing produces a further reduction in texture and average grain size (2.3 µm) and results in nearly isotropic room temperature deformation, a yield strength of 220 MPa, and an elongation of 23%. Particle stimulated nucleation of new grains by the β-phase during both dynamic and static recrystallization, is critical for achieving the low levels of texture. The influence of β-phase distribution in microstructure development is discussed.

Formability Analysis of Bamboo Fabric Reinforced Poly (Lactic) Acid Composites

PubMed Central

M. R., Nurul Fazita; Jayaraman, Krishnan; Bhattacharyya, Debes

2016-01-01

Poly (lactic) acid (PLA) composites have made their way into various applications that may require thermoforming to produce 3D shapes. Wrinkles are common in many forming processes and identification of the forming parameters to prevent them in the useful part of the mechanical component is a key consideration. Better prediction of such defects helps to significantly reduce the time required for a tooling design process. The purpose of the experiment discussed here is to investigate the effects of different test parameters on the occurrence of deformations during sheet forming of double curvature shapes with bamboo fabric reinforced-PLA composites. The results demonstrated that the domes formed using hot tooling conditions were better in quality than those formed using cold tooling conditions. Wrinkles were more profound in the warp direction of the composite domes compared to the weft direction. Grid Strain Analysis (GSA) identifies the regions of severe deformation and provides useful information regarding the optimisation of processing parameters. PMID:28773662

Theoretical analysis of sheet metal formability

NASA Astrophysics Data System (ADS)

Zhu, Xinhai

Sheet metal forming processes are among the most important metal-working operations. These processes account for a sizable proportion of manufactured goods made in industrialized countries each year. Furthermore, to reduce the cost and increase the performance of manufactured products, in addition to the environmental concern, more and more light weight and high strength materials have been used as a substitute to the conventional steel. These materials usually have limited formability, thus, a thorough understanding of the deformation processes and the factors limiting the forming of sound parts is important, not only from a scientific or engineering viewpoint, but also from an economic point of view. An extensive review of previous studies pertaining to theoretical analyses of Forming Limit Diagrams (FLDs) is contained in Chapter I. A numerical model to analyze the neck evolution process is outlined in Chapter II. With the use of strain gradient theory, the effect of initial defect profile on the necking process is analyzed. In the third chapter, the method proposed by Storen and Rice is adopted to analyze the initiation of localized neck and predict the corresponding FLDs. In view of the fact that the width of the localized neck is narrow, the deformation inside the neck region is constrained by the material in the neighboring homogeneous region. The relative rotation effect may then be assumed to be small and is thus neglected. In Chapter IV, Hill's 1948 yield criterion and strain gradient theory are employed to obtain FLDs, for planar anisotropic sheet materials by using bifurcation analysis. The effects of the strain gradient coefficient c and the material anisotropic parameters R's on the orientation of the neck and FLDs are analyzed in a systematic manner and compared with experiments. In Chapter V, Hill's 79 non-quadratic yield criterion with a deformation theory of plasticity is used along with bifurcation analyses to derive a general analytical expression for calculating FLDs. In the final chapter, a method is proposed to construct forming limit diagrams for sheet metals under different deformation histories. This analysis employs Hill's 79 anisotropic yield function and uses strain gradient theory to describe the constitutive equation for the flow stress. In order to utilize an analytical method developed earlier for proportional loading, the concept of "virtual deformation" is introduced. The actual deformation path is divided into a sequence of linear paths and an effective "virtual deformation" path is defined having a strain ratio identical to that of the linear part in the final deformation stage, and a plastic work identical to that of the prior actual deformation it is replacing. (Abstract shortened by UMI.)

Growth Kinetics of Magnesio-Aluminate Spinel in Al/Mg Lamellar Composite Interface

NASA Astrophysics Data System (ADS)

Fouad, Yasser; Rabeeh, Bakr Mohamed

The synthesis of Mg-Al2O3 double layered interface is introduced via the application of hot isostatic pressing, HIPing, in Al-Mg foils. Polycrystalline spinel layers are grown experimentally at the interfacial contacts between Al-Mg foils. The growth behavior of the spinel layers along with the kinetic parameters characterizing interface motion and long-range diffusion is established. Low melting depressant (LMD), Zn, and alloying element segregation tends to form micro laminated and/or Nano structure interphase in a lamellar composite solid state processing. Nano composite ceramic interphase materials offer interesting mechanical properties not achievable in other materials, such as superplastic flow and metal-like machinability. Microstructural characterization, mechanical characterization is also established via optical microscopy scanning electron microscopy, energy dispersive X-ray spectroscopy and tensile testing. Chemical and mechanical bonding via inter diffusion processing with alloy segregation are dominant for interphase kinetics. Mechanical characterization with interfacial shear strength is also introduced. HIPing processing is successfully applied on 6082 Al-alloy and AZ31 magnesium alloy for either particulate or micro-laminated interfacial composite processing. The interphase kinetic established through localized micro plasticity, metal flow, alloy segregation and delocalized Al oxide and Mg oxide. The kinetic of interface/interphase induce new nontraditional crack mitigation a long with new bridging and toughening mechanisms.

Kinetic theory for the formation of diamond nanothreads with desired configurations: a strain-temperature controlled phase diagram.

PubMed

Gao, Junfeng; Zhang, Gang; Yakobson, Boris I; Zhang, Yong-Wei

2018-05-24

Diamond nanothreads (DNTs) are a brand-new one-dimensional carbon nanomaterial that was synthesized recently by compressing benzene. Compared with sp2 carbon nanotubes, DNTs may possess a much higher interfacial load-transfer ability. However, previous studies have shown that the mechanical properties of DNTs are highly sensitive to the composition of Stone-Wales (SW) transformed sites. Up to now, it remained unclear what roles SWs play in the structure stability and how to engineer its molecular structure for novel mechanical properties. Using ab initio calculations, here we show that the most stable structure of a DNT is composed of alternative SW and hydrogenated carbon nanotube (3,0) units, suggesting that SW plays an essential role in stabilizing DNT. Interestingly, we found that the SW transition barrier is a nearly linear function of the applied strain, enabling strain engineering of its molecular structure. To do so, we propose a strain-temperature-stretching rate phase diagram to guide the construction of desired molecular structures to achieve superplastic behavior of DNTs. Our findings not only enrich our understanding of this novel carbon material, but also provide a strategy to control its structural and mechanical properties for novel applications, such as energy absorption, energy storage and materials reinforcement.

Properties of WZ21 (%wt) alloy processed by a powder metallurgy route.

PubMed

Cabeza, Sandra; Garcés, Gerardo; Pérez, Pablo; Adeva, Paloma

2015-06-01

Microstructure, mechanical properties and corrosion behaviour of WZ21 (%wt) alloy prepared by a powder metallurgy route from rapidly solidified powders have been studied. Results were compared to those of the same alloy prepared through a conventional route of casting and extrusion. The microstructure of the extruded ingot consisted of α-Mg grains and Mg3Zn3Y2 (W-phase) and LPSO-phase particles located at grain boundaries. Moreover, stacking faults were also observed within α-Mg grains. The alloy processed by the powder metallurgy route exhibited a more homogeneous and finer microstructure, with a grain size of 2 μm. In this case W-phase and Mg24Y5 phase were identified, but not the LPSO-phase. The microstructural refinement induced by the use of rapidly solidified powders strengthened the alloy at room temperature and promoted superplasticity at higher strain rates. Corrosion behaviour in PBS medium evidenced certain physical barrier effect of the almost continuous arrangements of second phases aligned along the extrusion direction in conventionally processed WZ21 alloy, with a stable tendency around 7 mm/year. On the other hand, powder metallurgy processing promoted significant pitting corrosion, inducing accelerated corrosion rate during prolonged immersion times. Copyright © 2015 Elsevier Ltd. All rights reserved.

A Novel Microcharacterization Technique in the Measurement of Strain and Orientation Gradient in Advanced Materials

NASA Technical Reports Server (NTRS)

Garmestai, H.; Harris, K.; Lourenco, L.

1997-01-01

Representation of morphology and evolution of the microstructure during processing and their relation to properties requires proper experimental techniques. Residual strains, lattice distortion, and texture (micro-texture) at the interface and the matrix of a layered structure or a functionally gradient material and their variation are among parameters important in materials characterization but hard to measure with present experimental techniques. Current techniques available to measure changes in interred material parameters (residual stress, micro-texture, microplasticity) produce results which are either qualitative or unreliable. This problem becomes even more complicated in the case of a temperature variation. These parameters affect many of the mechanical properties of advanced materials including stress-strain relation, ductility, creep, and fatigue. A review of some novel experimental techniques using recent advances in electron microscopy is presented here to measure internal stress, (micro)texture, interracial strength and (sub)grain formation and realignment. Two of these techniques are combined in the chamber of an Environmental Scanning Electron Microscope to measure strain and orientation gradients in advanced materials. These techniques which include Backscattered Kikuchi Diffractometry (BKD) and Microscopic Strain Field Analysis are used to characterize metallic and intermetallic matrix composites and superplastic materials. These techniques are compared with the more conventional x-ray diffraction and indentation techniques.

Time-lapse nanoscopy of friction in the non-Amontons and non-Coulomb regime.

PubMed

Ishida, Tadashi; Sato, Takaaki; Ishikawa, Takahiro; Oguma, Masatsugu; Itamura, Noriaki; Goda, Keisuke; Sasaki, Naruo; Fujita, Hiroyuki

2015-03-11

Originally discovered by Leonard da Vinci in the 15th century, the force of friction is directly proportional to the applied load (known as Amontons' first law of friction). Furthermore, kinetic friction is independent of the sliding speed (known as Coulomb's law of friction). These empirical laws break down at high normal pressure (due to plastic deformation) and low sliding speed (in the transition regime between static friction and kinetic friction). An important example of this phenomenon is friction between the asperities of tectonic plates on the Earth. Despite its significance, little is known about the detailed mechanism of friction in this regime due to the lack of experimental methods. Here we demonstrate in situ time-lapse nanoscopy of friction between asperities sliding at ultralow speed (∼0.01 nm/s) under high normal pressure (∼GPa). This is made possible by compressing and rubbing a pair of nanometer-scale crystalline silicon anvils with electrostatic microactuators and monitoring its dynamical evolution with a transmission electron microscope. Our analysis of the time-lapse movie indicates that superplastic behavior is induced by decrystallization, plastic deformation, and atomic diffusion at the asperity-asperity interface. The results hold great promise for a better understanding of quasi-static friction under high pressure for geoscience, materials science, and nanotechnology.

Numerical analysis of back pressure equal channel angular pressing of an Al-Mg alloy

NASA Astrophysics Data System (ADS)

Comăneci, R.

2017-08-01

Ultrafine grain size provides enhanced mechanical and/or physical properties such as strength and high ductility, superplasticity at relatively low temperatures and high strain rate and better corrosion resistance. Well-known as one of the most promising and effective structure refining method among other severe plastic deformation (SPD) techniques, equal channel angular pressing (ECAP) has been intensively investigated due to spectacular improvements in structure and therefore properties of bulk ultrafine grained/nanostructured materials. A successful ECAP requires surpassing two obstacles: the necessary load level which directly affects tools and a favourable stress distribution so the material withstanding the accumulated strain of repeated deformation. Materials could withstand more passes if a back pressure (BP) is applied. In traditional ECAP, tensile stress along the contact surface between the work piece and the upper wall of the outlet channel leads to crack initiation, while in the presence of BP, a negative (compressive) stress appears during the process balancing the tensile stress. In this study a comparative tridimensional finite element analysis (FEA) is performed to evaluate the flow of an Al-Mg alloy depending on different BP levels and process parameters. The results in terms of load level and strain distribution show the influence of BP on the material behaviour, opening opportunities for industrial applications.

Investigations on the micro-scale surface interactions at the tool and workpiece interface in micro-manufacturing of bipolar plates for proton exchange membrane fuel cells

NASA Astrophysics Data System (ADS)

Peker, Mevlut Fatih

Micro-forming studies have been more attractive in recent years because of miniaturization trend. One of the promising metal forming processes, micro-stamping, provides durability, strength, surface finish, and low cost for metal products. Hence, it is considered a prominent method for fabricating bipolar plates (BPP) with micro-channel arrays on large metallic surfaces to be used in Proton Exchange Membrane Fuel Cells (PEMFC). Major concerns in micro-stamping of high volume BPPs are surface interactions between micro-stamping dies and blank metal plates, and tribological changes. These concerns play a critical role in determining the surface quality, channel formation, and dimensional precision of bipolar plates. The surface quality of BPP is highly dependent on the micro-stamping die surface, and process conditions due to large ratios of surface area to volume (size effect) that cause an increased level of friction and wear issues at the contact interface. Due to the high volume and fast production rates, BPP surface characteristics such as surface roughness, hardness, and stiffness may change because of repeated interactions between tool (micro-forming die) and workpiece (sheet blank of interest). Since the surface characteristics of BPPs have a strong effect on corrosion and contact resistance of bipolar plates, and consequently overall fuel cell performance, evolution of surface characteristics at the tool and workpiece should be monitored, controlled, and kept in acceptable ranges throughout the long production cycles to maintain the surface quality. Compared to macro-forming operations, tribological changes in micro-forming process are bigger challenges due to their dominance and criticality. Therefore, tribological size effect should be considered for better understanding of tribological changes in micro-scale. The integrity of process simulation to the experiments, on the other hand, is essential. This study describes an approach that aims to investigate the surface topography changes during long-run micro-stamping of BPPs, and establish relationships between surface roughness--corrosion resistance and surface roughness-contact resistance characteristics of BPPs. Formability levels of formed BPPs and repeatability characteristics of the process were investigated. In addition, blank thickness changes, von-Mises stress, plastic strain levels and distributions of micro-stamping process were determined via finite element analysis (FEA). Test results revealed that the surface roughness change for the stamping dies and BPPs was unsteady (no trend) due to the continuous change of surface topography (i.e. asperity deformation). Sub-micron range local plastic deformations on stamping dies led to surface topography changes on BPP in long-run manufacturing case. As surface defects trigger corrosion, the correlation between surface roughness and corrosion resistance of BPPs was found to be direct. Increasing number of surface irregularities (asperities) lowered contact surface area that resulted in increased contact resistance. ZrN coated BPPs, on the other hand, did not change surface roughness, however; it improved the protection of BPPs against corrosion significantly. In addition, ZrN coating increased the conductivity of BPPs and reduced the contact resistance between BPP and gas diffusion layer (GDL), at certain extent. As dimensional stability and repeatability was confirmed in forming of both uncoated and coated BPPs during the long run manufacturing, different formability levels were achieved for coated and uncoated samples. Lower channel height values were obtained for coated plates because of the different surface hardness of uncoated and coated plates. In tribological size effect part of study, micro stamping experiments using three different dies with distinct channel height values at different stamping force levels were performed. It was concluded that decrease in forming die dimensions led to increase in coefficient of friction as previously reported by other researchers as one of the consequences of tribological size effect. On the other hand, coefficient of friction values were not affected by the force levels used in the experiments and simulations, whereas plastic strain, equivalent stress, and formability levels were increased with increasing stamping force, as expected. In essence, this study proposed a methodology to investigate the long-run manufacturing effects on dimensional stability and surface characteristics of micro-stamped sheets. It also correlates these parameters to fuel cell performance measures such as interfacial contact and corrosion resistance.

Role Of Impurities On Deformation Of HCP Crystal: A Multi-Scale Approach

NASA Astrophysics Data System (ADS)

Bhatia, Mehul Anoopkumar

Commercially pure (CP) and extra low interstitial (ELI) grade Ti-alloys present excellent corrosion resistance, lightweight, and formability making them attractive materials for expanded use in transportation and medical applications. However, the strength and toughness of CP titanium are affected by relatively small variations in their impurity/solute content (IC), e.g., O, Al, and V. This increase in strength is due to the fact that the solute either increases the critical stress required for the prismatic slip systems ({10- 10}) or activates another slip system ((0001), {10-11}). In particular, solute additions such as O can effectively strengthen the alloy but with an attendant loss in ductility by changing the behavior from wavy (cross slip) to planar nature. In order to understand the underlying behavior of strengthening by solutes, it is important to understand the atomic scale mechanism. This dissertation aims to address this knowledge gap through a synergistic combination of density functional theory (DFT) and molecular dynamics. Further, due to the long-range strain fields of the dislocations and the periodicity of the DFT simulation cells, it is difficult to apply ab initio simulations to study the dislocation core structure. To alleviate this issue we developed a multiscale quantum mechanics/molecular mechanics approach (QM/MM) to study the dislocation core. We use the developed QM/MM method to study the pipe diffusion along a prismatic edge dislocation core. Complementary to the atomistic simulations, the Semi-discrete Variational Peierls-Nabarro model (SVPN) was also used to analyze the dislocation core structure and mobility. The chemical interaction between the solute/impurity and the dislocation core is captured by the so-called generalized stacking fault energy (GSFE) surface which was determined from DFT-VASP calculations. By taking the chemical interaction into consideration the SVPN model can predict the dislocation core structure and mobility in the presence and absence of the solute/impurity and thus reveal the effect of impurity/solute on the softening/hardening behavior in alpha-Ti. Finally, to study the interaction of the dislocation core with other planar defects such as grain boundaries (GB), we develop an automated method to theoretically generate GBs in HCP type materials.

Experimentally validated computational modeling of organic binder burnout from green ceramic compacts

DOE Office of Scientific and Technical Information (OSTI.GOV)

Ewsuk, K.G.; Cochran, R.J.; Blackwell, B.F.

The properties and performance of a ceramic component is determined by a combination of the materials from which it was fabricated and how it was processed. Most ceramic components are manufactured by dry pressing a powder/binder system in which the organic binder provides formability and green compact strength. A key step in this manufacturing process is the removal of the binder from the powder compact after pressing. The organic binder is typically removed by a thermal decomposition process in which heating rate, temperature, and time are the key process parameters. Empirical approaches are generally used to design the burnout time-temperaturemore » cycle, often resulting in excessive processing times and energy usage, and higher overall manufacturing costs. Ideally, binder burnout should be completed as quickly as possible without damaging the compact, while using a minimum of energy. Process and computational modeling offer one means to achieve this end. The objective of this study is to develop an experimentally validated computer model that can be used to better understand, control, and optimize binder burnout from green ceramic compacts.« less

Effect of Morphological Differences on the Cold Formability of an Isothermally Heat-Treated Advanced High-Strength Steel

NASA Astrophysics Data System (ADS)

Weißensteiner, Irmgard; Suppan, Clemens; Hebesberger, Thomas; Winkelhofer, Florian; Clemens, Helmut; Maier-Kiener, Verena

2018-04-01

Steel sheets of Fe-0.2C-2Mn-0.2Si-0.03Ti-0.003B (m%) for the automotive industry were isothermally heat-treated, comprising austenitizing and subsequent isothermal annealing at temperatures between 300°C and 500°C. As a consequence, microstructures ranging from granular bainite over lower bainite to auto-tempered and untempered martensite were obtained. In tensile, hole expansion and bending tests, the performances in different forming conditions were compared and the changes of microstructure and texture were studied by complementary electron backscatter diffraction (EBSD) analyses. Samples with granular bainitic microstructures exhibited high total elongations but lower hole expansion ratios; in subsequent EBSD and texture analyses, evidence for inhomogeneous deformation was found. In contrast, the lath-like bainitic/martensitic microstructure showed higher strength and lower elongation to fracture. This results in a reduced bendability, but also in a high tolerance against damage induced by the shearing of edges, and, thus, allows homogeneous deformation to higher strains in the hole expansion test.

Improve the material absorption of light and enhance the laser tube bending process utilizing laser softening heat treatment

NASA Astrophysics Data System (ADS)

Imhan, Khalil Ibraheem; Baharudin, B. T. H. T.; Zakaria, Azmi; Ismail, Mohd Idris Shah B.; Alsabti, Naseer Mahdi Hadi; Ahmad, Ahmad Kamal

2018-02-01

Laser forming is a flexible control process that has a wide spectrum of applications; particularly, laser tube bending. It offers the perfect solution for many industrial fields, such as aerospace, engines, heat exchangers, and air conditioners. A high power pulsed Nd-YAG laser with a maximum average power of 300 W emitting at 1064 nm and fiber-coupled is used to irradiate stainless steel 304 (SS304) tubes of 12.7 mm diameter, 0.6 mm thickness and 70 mm length. Moreover, a motorized rotation stage with a computer controller is employed to hold and rotate the tube. In this paper, an experimental investigation is carried out to improve the laser tube bending process by enhancing the absorption coefficient of the material and the mechanical formability using laser softening heat treatment. The material surface is coated with an oxidization layer; hence, the material absorption of laser light is increased and the temperature rapidly rises. The processing speed is enhanced and the output bending angle is increased to 1.9° with an increment of 70% after the laser softening heat treatment.

Effect of mechanical treatment on intergranular corrosion of 6064 alloy bars

NASA Astrophysics Data System (ADS)

Sláma, P.; Nacházel, J.

2017-02-01

Aluminium Al-Mg-Si-type alloys (6xxx-series) exhibit good mechanical properties, formability, weldability and good corrosion resistance in various environments. They often find use in automotive industry and other applications. Some alloys, however, particularly those with higher copper levels, show increased susceptibility to intergranular corrosion. Intergranular corrosion (IGC) is typically related to the formation of microgalvanic cells between cathodic, more noble phases and depleted (precipitate-free) zones along grain boundaries. It is encountered mainly in AlMgSi alloys containing Cu, where it is thought to be related to the formation Q-phase precipitates (Al4Mg8Si7Cu2) along grain boundaries. The present paper describes the effects of mechanical working (extrusion, drawing and straightening) and artificial aging on intergranular corrosion in rods of the 6064 alloy. The resistance to intergranular corrosion was mapped using corrosion tests according to EN ISO 11846, method B. Corrosion tests showed dependence of corrosion type on mechanical processing of the material. Intergranular, pitting and transgranular corrosion was observed. Artificial ageing influenced mainly the depth of the corrosion.

Forming limit prediction by an evolving non-quadratic yield criterion considering the anisotropic hardening and r-value evolution

NASA Astrophysics Data System (ADS)

Lian, Junhe; Shen, Fuhui; Liu, Wenqi; Münstermann, Sebastian

2018-05-01

The constitutive model development has been driven to a very accurate and fine-resolution description of the material behaviour responding to various environmental variable changes. The evolving features of the anisotropic behaviour during deformation, therefore, has drawn particular attention due to its possible impacts on the sheet metal forming industry. An evolving non-associated Hill48 (enHill48) model was recently proposed and applied to the forming limit prediction by coupling with the modified maximum force criterion. On the one hand, the study showed the significance to include the anisotropic evolution for accurate forming limit prediction. On the other hand, it also illustrated that the enHill48 model introduced an instability region that suddenly decreases the formability. Therefore, in this study, an alternative model that is based on the associated flow rule and provides similar anisotropic predictive capability is extended to chapter the evolving effects and further applied to the forming limit prediction. The final results are compared with experimental data as well as the results by enHill48 model.

Novel strip-cast Mg/Al clad sheets with excellent tensile and interfacial bonding properties

PubMed Central

Kim, Jung-Su; Lee, Dong Ho; Jung, Seung-Pill; Lee, Kwang Seok; Kim, Ki Jong; Kim, Hyoung Seop; Lee, Byeong-Joo; Chang, Young Won; Yuh, Junhan; Lee, Sunghak

2016-01-01

In order to broaden industrial applications of Mg alloys, as lightest-weight metal alloys in practical uses, many efforts have been dedicated to manufacture various clad sheets which can complement inherent shortcomings of Mg alloys. Here, we present a new fabrication method of Mg/Al clad sheets by bonding thin Al alloy sheet on to Mg alloy melt during strip casting. In the as-strip-cast Mg/Al clad sheet, homogeneously distributed equi-axed dendrites existed in the Mg alloy side, and two types of thin reaction layers, i.e., γ (Mg17Al12) and β (Mg2Al3) phases, were formed along the Mg/Al interface. After post-treatments (homogenization, warm rolling, and annealing), the interfacial layers were deformed in a sawtooth shape by forming deformation bands in the Mg alloy and interfacial layers, which favorably led to dramatic improvement in tensile and interfacial bonding properties. This work presents new applications to multi-functional lightweight alloy sheets requiring excellent formability, surface quality, and corrosion resistance as well as tensile and interfacial bonding properties. PMID:27245687

Study of Impact Damage in PVA-ECC Beam under Low-Velocity Impact Loading Using Piezoceramic Transducers and PVDF Thin-Film Transducers.

PubMed

Qi, Baoxin; Kong, Qingzhao; Qian, Hui; Patil, Devendra; Lim, Ing; Li, Mo; Liu, Dong; Song, Gangbing

2018-02-24

Compared to conventional concrete, polyvinyl alcohol fiber reinforced engineering cementitious composite (PVA-ECC) offers high-strength, ductility, formability, and excellent fatigue resistance. However, impact-induced structural damage is a major concern and has not been previously characterized in PVA-ECC structures. We investigate the damage of PVA-ECC beams under low-velocity impact loading. A series of ball-drop impact tests were performed at different drop weights and heights to simulate various impact energies. The impact results of PVA-ECC beams were compared with mortar beams. A combination of polyvinylidene fluoride (PVDF) thin-film sensors and piezoceramic-based smart aggregate were used for impact monitoring, which included impact initiation and crack evolution. Short-time Fourier transform (STFT) of the signal received by PVDF thin-film sensors was performed to identify impact events, while active-sensing approach was utilized to detect impact-induced crack evolution by the attenuation of a propagated guided wave. Wavelet packet-based energy analysis was performed to quantify failure development under repeated impact tests.

An experimental investigation of energy absorption in TRIP steel under impact three-point bending deformation

NASA Astrophysics Data System (ADS)

Pham, Hang; Iwamoto, Takeshi

2015-09-01

TRIP (Transformation-induced Plasticity) steel is nowadays in widespread use in the automobile industry because of their favorable mechanical properties such as high strength, excellent formability and toughness because of strain-induced martensitic transformation. Moreover, when TRIP steel is applied to the components of the vehicles, it is expected that huge amount of kinetic energy will be absorbed into both plastic deformation and martensitic transformation during the collision. Basically, bending deformation due to buckling is one of the major crash deformation modes of automobile structures. Thus, an investigation of energy absorption during bending deformation at high impact velocity for TRIP steel is indispensable. Although TRIP steel have particularly attracted the recent interest of the scientific community, just few studies can be found on the energy absorption characteristic of TRIP steel, especially at impact loading condition. In present study, experimental investigations of bending deformation behaviors of TRIP steel are conducted in the three-point bending tests for both smooth and pre-cracked specimen. Then, energy absorption characteristic during plastic deformation and fracture process at high impact velocity in TRIP steel will be discussed.

Study of Impact Damage in PVA-ECC Beam under Low-Velocity Impact Loading Using Piezoceramic Transducers and PVDF Thin-Film Transducers

PubMed Central

Qian, Hui; Li, Mo; Liu, Dong; Song, Gangbing

2018-01-01

Compared to conventional concrete, polyvinyl alcohol fiber reinforced engineering cementitious composite (PVA-ECC) offers high-strength, ductility, formability, and excellent fatigue resistance. However, impact-induced structural damage is a major concern and has not been previously characterized in PVA-ECC structures. We investigate the damage of PVA-ECC beams under low-velocity impact loading. A series of ball-drop impact tests were performed at different drop weights and heights to simulate various impact energies. The impact results of PVA-ECC beams were compared with mortar beams. A combination of polyvinylidene fluoride (PVDF) thin-film sensors and piezoceramic-based smart aggregate were used for impact monitoring, which included impact initiation and crack evolution. Short-time Fourier transform (STFT) of the signal received by PVDF thin-film sensors was performed to identify impact events, while active-sensing approach was utilized to detect impact-induced crack evolution by the attenuation of a propagated guided wave. Wavelet packet-based energy analysis was performed to quantify failure development under repeated impact tests. PMID:29495277

Novel 1.5 GPa-strength with 50%-ductility by transformation-induced plasticity of non-recrystallized austenite in duplex steels.

PubMed

Sohn, Seok Su; Song, Hyejin; Jo, Min Chul; Song, Taejin; Kim, Hyoung Seop; Lee, Sunghak

2017-04-28

Needs for steel designs of ultra-high strength and excellent ductility have been an important issue in worldwide automotive industries to achieve energy conservation, improvement of safety, and crashworthiness qualities. Because of various drawbacks in existing 1.5-GPa-grade steels, new development of formable cold-rolled ultra-high-strength steels is essentially needed. Here we show a plausible method to achieve ultra-high strengths of 1.0~1.5 GPa together with excellent ductility above 50% by actively utilizing non-recrystallization region and TRansformation-Induced Plasticity (TRIP) mechanism in a cold-rolled and annealed Fe-Mn-Al-C-based steel. We adopt a duplex microstructure composed of austenite and ultra-fine ferrite in order to overcome low-yield-strength characteristics of austenite. Persistent elongation up to 50% as well as ultra-high yield strength over 1.4 GPa are attributed to well-balanced mechanical stability of non-crystallized austenite with critical strain for TRIP. Our results demonstrate how the non-recrystallized austenite can be a metamorphosis in 1.5-GPa-grade steel sheet design.

Establishing the relationship between manufacturing and component performance in stretch formed thermoplastic composites

NASA Technical Reports Server (NTRS)

Santare, Michael H.; Pipes, R. Byron; Beaussart, A. J.; Coffin, D. W.; Otoole, B. J.; Shuler, S. F.

1993-01-01

Flexible manufacturing methods are needed to reduce the cost of using advanced composites in structural applications. One method that allows for this is the stretch forming of long discontinuous fiber materials with thermoplastic matrices. In order to exploit this flexibility in an economical way, a thorough understanding of the relationship between manufacturing and component performance must be developed. This paper reviews some of the recent work geared toward establishing this understanding. Micromechanics models have been developed to predict the formability of the material during processing. The latest improvement of these models includes the viscoelastic nature of the matrix and comparison with experimental data. A finite element scheme is described which can be used to model the forming process. This model uses equivalent anisotropic viscosities from the micromechanics models and predicts the microstructure in the formed part. In addition, structural models have been built to account for the material property gradients that can result from the manufacturing procedures. Recent developments in this area include the analysis of stress concentrations and a failure model each accounting for the heterogeneous material fields.

Novel strip-cast Mg/Al clad sheets with excellent tensile and interfacial bonding properties.

PubMed

Kim, Jung-Su; Lee, Dong Ho; Jung, Seung-Pill; Lee, Kwang Seok; Kim, Ki Jong; Kim, Hyoung Seop; Lee, Byeong-Joo; Chang, Young Won; Yuh, Junhan; Lee, Sunghak

2016-06-01

In order to broaden industrial applications of Mg alloys, as lightest-weight metal alloys in practical uses, many efforts have been dedicated to manufacture various clad sheets which can complement inherent shortcomings of Mg alloys. Here, we present a new fabrication method of Mg/Al clad sheets by bonding thin Al alloy sheet on to Mg alloy melt during strip casting. In the as-strip-cast Mg/Al clad sheet, homogeneously distributed equi-axed dendrites existed in the Mg alloy side, and two types of thin reaction layers, i.e., γ (Mg17Al12) and β (Mg2Al3) phases, were formed along the Mg/Al interface. After post-treatments (homogenization, warm rolling, and annealing), the interfacial layers were deformed in a sawtooth shape by forming deformation bands in the Mg alloy and interfacial layers, which favorably led to dramatic improvement in tensile and interfacial bonding properties. This work presents new applications to multi-functional lightweight alloy sheets requiring excellent formability, surface quality, and corrosion resistance as well as tensile and interfacial bonding properties.

Effect of Evolutionary Anisotropy on Earing Prediction in Cylindrical Cup Drawing

NASA Astrophysics Data System (ADS)

Choi, H. J.; Lee, K. J.; Choi, Y.; Bae, G.; Ahn, D.-C.; Lee, M.-G.

2017-05-01

The formability of sheet metals is associated with their planar anisotropy, and finite element simulations have been applied to the sheet metal-forming process by describing the anisotropic behaviors using yield functions and hardening models. In this study, the evaluation of anisotropic constitutive models was performed based on the non-uniform height profile or earing in circular cylindrical cup drawing. Two yield functions, a quadratic Hill1948 and a non-quadratic Yld2000-2d model, were used under non-associated and associated flow rules, respectively, to simultaneously capture directional differences in yield stress and r value. The effect of the evolution of anisotropy on the earing prediction was also investigated by employing simplified equivalent plastic strain rate-dependent anisotropic coefficients. The computational results were in good agreement with experiments when the proper choice of the yield function and flow rule, which predicts the planar anisotropy, was made. Moreover, the accuracy of the earing profile could be significantly enhanced if the evolution of anisotropy between uniaxial and biaxial stress states was additionally considered.

Mechanical and Metallurgical Evolution of Stainless Steel 321 in a Multi-step Forming Process

NASA Astrophysics Data System (ADS)

Anderson, M.; Bridier, F.; Gholipour, J.; Jahazi, M.; Wanjara, P.; Bocher, P.; Savoie, J.

2016-04-01

This paper examines the metallurgical evolution of AISI Stainless Steel 321 (SS 321) during multi-step forming, a process that involves cycles of deformation with intermediate heat treatment steps. The multi-step forming process was simulated by implementing interrupted uniaxial tensile testing experiments. Evolution of the mechanical properties as well as the microstructural features, such as twins and textures of the austenite and martensite phases, was studied as a function of the multi-step forming process. The characteristics of the Strain-Induced Martensite (SIM) were also documented for each deformation step and intermediate stress relief heat treatment. The results indicated that the intermediate heat treatments considerably increased the formability of SS 321. Texture analysis showed that the effect of the intermediate heat treatment on the austenite was minor and led to partial recrystallization, while deformation was observed to reinforce the crystallographic texture of austenite. For the SIM, an Olson-Cohen equation type was identified to analytically predict its formation during the multi-step forming process. The generated SIM was textured and weakened with increasing deformation.

Numerical simulation of multi-layered textile composite reinforcement forming

DOE Office of Scientific and Technical Information (OSTI.GOV)

Wang, P.; Hamila, N.; Boisse, P.

2011-05-04

One important perspective in aeronautics is to produce large, thick or/and complex structural composite parts. The forming stage presents an important role during the whole manufacturing process, especially for LCM processes (Liquid Composites Moulding) or CFRTP (Continuous Fibre Reinforcements and Thermoplastic resin). Numerical simulations corresponding to multi-layered composite forming allow the prediction for a successful process to produce the thick parts, and importantly, the positions of the fibres after forming to be known. This paper details a set of simulation examples carried out by using a semi-discrete shell finite element made up of unit woven cells. The internal virtual workmore » is applied on all woven cells of the element taking into account tensions, in-plane shear and bending effects. As one key problem, the contact behaviours of tool/ply and ply/ply are described in the numerical model. The simulation results not only improve our understanding of the multi-layered composite forming process but also point out the importance of the fibre orientation and inter-ply friction during formability.« less

Anisotropy influence on the failure of Ti6Al4V sheets deformed at room and elevated temperature

NASA Astrophysics Data System (ADS)

Wang, Q. L.; Ghiotti, A.; Bruschi, S.

2018-05-01

Ti6Al4V sheets are usually difficult-to-form at room temperature as a consequence of their strong basal texture and hcp crystal lattice. The heating of the alloy below the beta transus temperature is recognized to enhance its formability, reducing the flow stress and increasing the ductility. However, the influence of the sheet anisotropy on the material failure hasn't been studied yet. To this aim, the paper presents the anisotropy influence on the failure characteristics of Ti6Al4V titanium alloy sheets making use of tensile tests carried out at room temperature and 600°C on smooth, notched and shear samples in order to have various stress states. The fracture strain is measured and the effect of the sample orientation and stress state is identified. To determine the actual stress state for each sample geometry, a numerical model is set up and calibrated using elasto-plastic data from uni-axial tensile tests on smooth samples. Finally, the fracture surfaces are observed through SEM analysis to explain the failure characteristics.