The fingerprint of deformation in materials at large strains and at high strain rates is the formation of adiabatic shear bands. Adiabatic shear bands lead to unexpected failure of materials during service. This study investigated the possibility of eliminating adiabatic shear bands from materials subjected to severe deformation at high strain rates by post impact heat treatment. Five groups of cylindrical AISI 4340 steel samples were impacted using the Direct Impact Hopkinson Pressure Bar (DIHPB) developed at the University of Manitoba. Selected impacted samples with distinct transformed shear bands were soaked at 350⁰C to 850⁰C for periods ranging from 30 minutes to 4 hours to investigate how temperature and time affects the properties and structure of the shear bands. Annealing the shear bands at 350⁰C resulted in an increase in hardness of the shear bands and the surrounding material outside the shear bands regardless of the heat treatment before impact, amount of deformation, and the time of annealing. Significant decrease in hardness of the shear bands occurred after post impact annealing at 650⁰C for 30 minutes and 2 hours. Hardness of the shear bands reduced to the same level as that of the impacted material outside the shear bands. However, the initial path of the shear bands in the impacted steel samples could be traced through a “signature” left after the annealing. Post-impact annealing of the steel samples at 750⁰C and 850⁰C resulted in a homogenous microstructure with no trace of the shear bands. The “signatures” which were used to trace the path of the shear bands in impacted samples annealed at 650⁰C disappeared and the hardness across the samples became uniform. The observations from this study show that adiabatic shear bands in typical steel can be eliminated by annealing heat treatment. The temperature of annealing is the most critical parameter and the annealing should be performed above 650⁰C.

This research, is initiated to systematically study the microstructure of AISI 4340 steel prior to impact, after impact and after post-impact annealing to determine the effect of the pre-deformation microstructure on the nucleation and initiation of ASBs, and the mechanism of evolution of ASBs during impact. This study used state-of-the-art microstructural characterization techniques such as the FIB and STEM/HRTEM to reveal that initial microstructural inhomogeneity produces nucleation sites for the initiation of ASBs during impact. It was observed that double misfit interfaces and boundary layers, formed around precipitated carbides (interface between reinforcements and matrix), increased the volume fraction of dislocation sources within the pre-impact specimens. It is demonstrated that the intersection of an activated dislocation source with the direction of maximum shear (regions of stress concentrations) within the specimens during impact, is a necessary condition for the points of intersection to act as possible sites for the nucleation and initiation of ASB depending on the rate of dislocation generation, local strain and strain rate. In addition, the structure that evolves after strain localization starts out with elongation of the grains in the shear direction with the initiation of random and transverse dislocation boundaries along the elongated grains. The elongated grains break along the initiated dislocation boundaries as strain/strain rate increases resulting in the creation of smaller elongated-broken grains and nanograins. Boundary refinement of the broken grains occurring through grain rotation and adiabatic heating results in the evolution of refined grains, subgrains and nanograins. The presence of elongated grains, broken grains, refined grains, subgrains and nanograins within the evolved shear band structures demonstrate that the local deformation is dependent on the imposed local strain and strain rate and that these mechanisms occur concurrently during impact. The results obtained, which are specific to the behavior of BCC ferritic Pearlitic hardenable steels, lead to the conclusion that the evolution of ASBs is a simultaneous layering of microstructures initially driven by dislocations which produce the final structures observed in the shear bands at the end of passage of the stress wave. / February 2015

The purpose of the work presented in this thesis was to explore and understand the mechanisms governing toughness, ductility and ballistic performance in a class of nanostructured carbide-free bainite-austenite steels, sometimes known as ‘superbainite’. The mechanical properties of these alloys have been extensively reported, but their interpretation is not clear. The thesis begins with an introduction to both the relevant nanostructures and some of the difficulties involved in explaining observed properties, alongside a summary of the role of mixed- microstructures in alloy development. An overview of the debate regarding the mechanism of bainite formation is pre- sented in Chapter 2, in the form of a literature survey encompassing the period of explicit recognition of the bainite microstructure. Of note is the role played by the displacive theory of formation in the development of the alloy structures investigated in this thesis. A characterisation of a commonly available bainitic alloy forms the basis for Chapter 4. Observations confirm the nanoscale nature of the structure, although additional phases are found to be present, namely: cementite and martensite. This is explained as resulting from relatively low alloying additions and chem- ical segregation effects, which are modelled using thermodynamic and kinetic approaches. Chapters 5 and 6 contain a comprehensive study of the response of this alloy to the stress concentration present at the notch root of a Charpy impact sample. The work provides evidence of notch root embrittlement due to stress-induced martensite transformation. Results from synchrotron and laboratory X-ray experiments in particular reveal that machining, as well as applied stress, can initiate the austenite-martensite transformation, and methods to mitigate this effect are suggested. An innovative approach is harnessed in Chapter 7, in order to identify exper- imentally the volume fraction at which three-dimensional connectivity (‘percolation’) of austenite is lost in a superbainitic steel. Hydrogen thermal desorption techniques are applied to this problem, inspired by the tendency of such alloys to undergo tensile failure with limited or zero necking. The striking result sheds light on the importance of austenite morphology in restricting the diffusion of hydrogen into a mixed structure. The final set of experimental work is directed towards understanding the damage mechanisms that occur during projectile penetration of a coarser bainitic armour- plate alloy. The formation of adiabatic shear bands is found to be a dominant factor governing the ballistic failure of the plate. The sheared material undergoes severe high-temperature deformation, but does not change phase upon cooling, leading to the proposal of certain methods that could be implemented to improve ballistic resistance of the steel. The totality of the research presented herein is summarised in Chapter 9, which draws attention to new areas of interest that have arisen from the current work, proposing several future directions of investigation. The broader issue of understanding, common to all studies performed thus far, is that of the causes, effects, and extent, of stress-induced transformation to martensite experienced by the retained austenite that is a key feature of superbainite and similar steels.

We have developed a third-order shear and normal deformable plate/shell theory (TSNDT) incorporating all geometric nonlinearities and used it to analyze, by the finite element method (FEM), transient finite deformations of a sandwich beam with two face sheets and the core made of St. Venant-Kirchhoff materials.  A triangular cohesive zone model with stress based criterion for delamination initiation and energy based relation for complete separation is used to analyze delamination failure in a beam under mixed-mode loading. We have studied transient post-buckling deformations and delamination progression in an axially compressed and initially delaminated clamped-clamped sandwich beam.  The buckling load for transient deformations exceeds that for static deformations and the increase depends upon the loading rate.  This FE software for analyzing deformations of sandwich beam is coupled with that based on the boundary element method (BEM) for studying time-dependent deformations of water and the coupled software is used to analyze deformations of flexible curved hulls due to water slamming loads.  The water is assumed to be inviscid and incompressible and undergo irrotational deformations.  The Laplace equation for the velocity potential is numerically solved by the BEM with normal velocity and pressure assumed to be continuous across the interface between the hull and the water.  Challenging issues resolved in this work include finding the wetted surface of the hull, nonlinear deformations of the fluid due to convective part of acceleration, effects of geometric nonlinearities on hull\'s deformations, resolution of the jet tip, as well as the initiation and propagation of delamination between the face sheets and the core.  It is found that both delamination and geometric nonlinearities significantly affect the hydrodynamic pressure acting on the hull, and transverse shear deformations contribute more to the strain energy absorbed by the core than its transverse normal deformations.  <br />We have used the discontinuous basis functions to derive the Galerkin formulation of a nonlinear problem involving simple shearing deformations of a homogeneous and isotropic thermo-elasto-visco-plastic body with uniform deformations perturbed to simulate the effect of a defect.  The resulting coupled nonlinear ordinary differential equations are integrated with respect to time by using the package, LSODE (Livermore Solver for Ordinary Differential Equations).  Computed results showing localization of deformations into narrow regions are found to agree well with those found by the FEM, and spatial variations of the shear stress are smoother than those obtained by the FEM.<br /><br /> / Ph. D.

Fundamental understanding of high strain rate deformation behavior of materials is critical in designing new alloys for wide-ranging applications including military, automobile, spacecraft, and industrial applications. High entropy alloys, consisting of multiple elements in (near) equimolar proportions, represent a new paradigm in structural alloy design providing ample opportunity for achieving excellent performance in high strain rate applications by proper selection of constituent elements and/or thermomechanical processing. This dissertation is focused on fundamental understanding of high strain-rate deformation behavior of several high entropy alloy systems with widely varying microstructures. Ballistic impact testing of face centered cubic Al0.1CoCrFeNi high entropy alloy showed failure by ductile hole growth. The deformed microstructure showed extensive micro-banding and micro-twinning at low velocities while adiabatic shear bands and dynamic recrystallization were seen at higher velocities. The Al0.7CoCrFeNi and AlCoCrFeNi2.1 eutectic high entropy alloys, with BCC and FCC phases in lamellar morphology, showed failure by discing. A network of cracks coupled with small and inhomogeneous plastic deformation led to the brittle mode of failure in these eutectic alloys. Phase-specific mechanical behavior using small-scale techniques revealed higher strength and strain rate sensitivity for the B2 phase compared to the L12 phase. The interphase boundary demonstrated good stability without any cracks at high compressive strain rates. The Al0.3CoCrFeNi high entropy alloy with bimodal microstructure demonstrated an excellent combination of strength and ductility. Ballistic impact testing of Al0.3CoCrFeNi alloy showed failure by ductile hole growth and demonstrated superior performance compared to all the other high entropy alloy systems studied. The failure mechanism was dominated by micro-banding, micro-twining, and adiabatic shear localization. Comparison of all the high entropy alloy systems with currently used state-of-the-art rolled homogenous armor (RHA) steel showed a strong dependence of failure modes on microstructural features.