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Includes reprints of author's related articles. / Bibliography: pages 187-201. / The competition between microfracture and plastic flow has been studied in relation to the thermomechanical processing parameters and minor element chemistry of wrought super-ferritic alloys based on a composition of Fe-40wt% Cr. These alloys have been developed for corrosion-resistant applications, specifically by micro-alloying with platinum group metals to induce cathodic modification, but their use has been hampered by inadequate toughness at ambient temperatures. Brittle cleavage of the alloys is a consequence of the high resistance to plastic flow required to accommodate local stresses, such as those found ahead of a loaded crack. Once initiated, a crack propagates in a brittle manner with minimal ductility. The impact toughness therefore relies on the ability of the alloys to withstand crack initiation. The frequency of the crack initiation events is related to the distribution of secondary phases within the matrix and at the grain boundaries. A direct means of improving the toughness and the ductility is accordingly via annealing cycles and minor alloying additions to control the precipitation of second phases. The ductility is enhanced by raising the mobile dislocation density, and this may be achieved by pre-straining recrystallised material, or increasing the number of dislocation sources in the otherwise source-poor material. The generation of mobile dislocations by prismatic punching at second phase particles in response to local or tessellated stresses was found to increase the ductility and the impact toughness of the alloy. The addition of nickel also increases the brittle fracture resistance by promoting stress accommodation at the crack tip, a result which can, in principle, be explained on the basis of enhanced dislocation dynamics. The tendency of the alloys to form a stable recovered substructure was identified as a critical parameter for both the mechanical and corrosion properties. The low-angle dislocation sub-arrays contribute to overall strain-hardening, but destabilise the passivity of the alloys in acid media. In practice, rationalisation of the microstructural parameters has enabled the practicable fabrication of tough, corrosion-resistant alloys, suitable for commercial development.

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Abstract Friction stir processing (FSP) is modified to produce various grain sizes of aluminum matrix composites (Al-Al2O3, Al-Zn-Al2O3 and Al-Zn) ranging from 300 nm to 3£gm. The microstructures of the composites were characterized using SEM and TEM. Tensile tests were performed to evaluate the mechanical properties of these composites. In the Al-Al2O3 system, it was found that the nano-scale alumina made it very effective to accumulate dislocations within grains during deformation, and resulted in increasing working hardening rate which is very critical to extend uniform elongation for materials with submicron grain sizes. In the Al-Zn-Al2O3 system, addition of Zn which dissolved into Al matrix to form solid solution and subsequently uniformly distributed G-P zones can improve strength and uniform ductility to some extent, comparing to those without addition of Zn. In addition, the relaxed and dislocation-free boundaries were observed regardless the existence of Al2O3 particles on boundaries. As a result, ko derived from Hall-Petch equation from various strain region decrease as Zn increases. In the Al-Zn system, experimental evidence suggests that increasing Zn content from 0 to 15wt% can enhance the total elongation but not uniform elongation as a result of the uniform spreading of the fine slip bands all over the gauge length and the contribution of grain boundary sliding (GBS) at RT. The relaxed and dislocation-free boundaries and GBS are attributed to the combination of high fraction of high-angle GBs and high GB diffusion to help fast dislocations annihilation at boundaries.

Hydrogen Embrittlement (HE) is a very common failure mechanism induced crack propagation in materials that are utilized in oil and gas industry structural components and equipment. Considering the prediction of HE behavior, which is suggested in this study, is one technique of monitoring HE of equipment in service. Therefore, multi-scale constitutive models that account for the failure in polycrystalline Body Centered Cubic (BCC) materials due to hydrogen embrittlement are developed. The polycrystalline material is modeled as two-phase materials consisting of a grain interior (GI) phase and a grain boundary (GB) phase. In the first part of this work, the hydrogen concentration in the GI (Cgi) and the GB (Cgb) as well as the hydrogen distribution in each phase, were calculated and modeled by using kinetic regime-A and C, respectively. In the second part of this work, this dissertation captures the adverse effects of hydrogen concentration, in each phase, in micro/meso and macro-scale models on the mechanical behavior of steel; e.g. tensile strength and critical porosity. The models predict the damage mechanisms and the reduction in the ultimate strength profile of a notched, round bar under tension for different hydrogen concentrations as observed in the experimental data available in the literature for steels. Moreover, the study outcomes are supported by the experimental data of the Fractography and HE indices investigation. In addition to the aforementioned continuum model, this work employs the Molecular Dynamics (MD) simulations to provide information regarding bond formulation and breaking. The MD analyses are conducted for both single grain and polycrystalline BCC iron with different amounts of hydrogen and different size of nano-voids. The simulations show that the hydrogen atoms could form the transmission in materials configuration from BCC to FCC (Face Centered Cubic) and HCP (Hexagonal Close Packed). They also suggest the preferred sites of hydrogen for each case. The connections between the results for different scales (nano, micro/meso and macro-scale) were suggested in this dissertation and show good agreements between them. We finally conclude that hydrogen-induced steel fracture and the change of fracture mode are caused by the suppression of dislocation emission at crack tip and changing in the material structure due to accumulation of hydrogen, which is driven by the stress fields. This causes the brittle fracture to occur as inter-granular in the GB and trans-granular in the GI.

Quantitative relationships among processing parameters, microstructure, and material properties are of considerable interest in the context of development of robust processing routes that optimize the required material properties. As a result, the scientific literature contains a large number of experimental and theoretical studies on microstructure-properties relationships. Fracture sensitive mechanical properties such as ductility, ultimate tensile strength, fatigue life, and fracture toughness depend on the average microstructural parameters as well as the distributions of microstructural parameters and their extrema.Development of quantitative relationships between such material properties and microstructural distributions and extrema has received considerably less attention, particularly in the wrought metals and alloys. Accordingly, an important objective of this research is to perform a systematic investigation in this direction. The dependence of the fracture-sensitive mechanical properties on the microstructural distributions and extrema often leads to substantial variability in these properties: a set of specimens having the same average chemistry, the same average processing history, and the same average microstructural parameters such as volume fractions of different constituents can exhibit substantially different material properties. The present research (i) is concerned with high strength (~ 1000 MPa) high martensite (>50%) dual phase steel where the martensite is a topologically continuous phase (matrix) containing a dispersion of islands of ferrite, and (ii) focuses on understanding the microstructural origins of the variability in fracture sensitive mechanical properties, in particular variability in the room temperature uniaxial tensile ductility. The research involves quantitative microstructure characterization using stereology and digital image processing and quantitative fractography using scanning electron microscopy (SEM) and fracture profilometry. The analysis of the quantitative fractographic and microstructural data obtained in this research leads to useful guidelines for reducing the variability in the tensile ductility of the dual phase steel under investigation.

In the Australian Standard, AS 3600-2001, the neutral axis parameter Ku is used as a convenient, but approximate, parameter to design for moment redistribution in building frames. The research work reported herein was conducted to obtain complete information regarding moment redistribution of beams and one-way slabs using 500 MPa steel reinforcement.A computer based iterative numerical method was developed to analyse reinforced two-span continuous concrete beams and one-way slabs. The method takes into account the material and geometrical non-linearities in the calculations. The deflected shape of the beam and one-way slab was calculated by dividing the span length into a number of rigid segments. The program also calculates the failure load and extent of moment redistribution. The analytical method was verified against the test results reported in the literature. The analytical results for load-deflection graphs and moment redistribution showed a good agreement with the test results.A parametric study was conducted using analytical method. The results of this study showed that moment redistribution depends not only on the neutral axis parameter (Ku) but also on the ratio of neutral axis parameter (Ku-/Ku+), ultimate steel strain (ªsu) and concrete compressive strength (fc).

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