The objective of this work is to develop an evolution equation for the ductile growth of a spherical void in a highly strain rate and temperature dependent material. The material considered in this work is stainless steel 304L at 982 °C. The material is characterized by a physically-based internal state variable model derived within consistent kinematics and thermodynamics — Evolving Microstructure Model for Inelasticity. Through this formulation, the degradation of the elastic moduli due to damage has been naturally acquired. An elastoviscoplasticity user material subroutine has also been developed and implemented into a commercially available finite element software ABAQUS. The subroutine utilizes a return mapping algorithm, where a purely elastic trial state (elastic predictor) is followed by a plastic corrector phase (return mapping). A conditionally stable fully-implicit scheme, derived from the backward Euler integration method, has been employed to calculate the values of the internal state variables in the elastoviscoplasticity integration routine. A repeating unit cell problem is set up by introducing a spherical void inside a matrix material that simulates a periodic array of voids in a component. Using finite element analysis, a database is generated by recording the responses of the unit cell under various combinations of loading conditions, porosity, and state variables. Functional forms of the void growth equations are constructed by utilizing normalization techniques to collapse all the data into master curves. The evolution equations are converted to a form consistent with the continuum damage variable in the complete thermal-elastic-plastic-damage version of the physically-based internal state variable model.

In the combustion zone of industrial- and aero- gas turbines, thermomechanical fatigue (TMF) is the dominant damage mechanism. Thermomechanical fatigue is a coupling of independent creep, fatigue, and oxidation damage mechanisms that interact and accelerate microstructural degradation. A mixture of intergranular cracking due to creep, transgranular cracking due to fatigue, and surface embrittlement due to oxidation is often observed in gas turbine components removed from service. The current maintenance scheme for gas turbines is to remove components from service when any criteria (elongation, stress-rupture, crack length, etc.) exceed the designed maximum allowable. Experimental, theoretical, and numerical analyses are performed to determine the state of the component as it relates to each criterion (a time consuming process). While calculating these metrics individually has been successful in the past, a better approach would be to develop a unified mechanical modeling that incorporates the constitutive response, microstructural degradation, and rupture of the subject material via a damage variable used to predict the cumulative “damage state” within a component. This would allow for a priori predictions of microstructural degradation, crack propagation/arrest, and component-level lifing. In this study, a unified mechanical model for creep-fatigue (deformation, cracking, and rupture) is proposed. It is hypothesized that damage quantification techniques can be used to develop accurate creep, fatigue, and plastic/ductile cumulative- nonlinear- damage laws within the continuum damage mechanics principle. These damage laws when coupled with appropriate constitutive equations and a degrading stiffness tensor can be used to predict the mechanical state of a component. A series of monotonic, creep, fatigue, and tensile-hold creepfatigue tests are obtained from literature for 304 stainless steel at 600°C (1112°F) in an air. iv Cumulative- nonlinear- creep, fatigue, and a coupled creep-fatigue damage laws are developed. The individual damage variables are incorporated as an internal state variable within a novel unified viscoplasticity constitutive model (zero yield surface) and degrading stiffness tensor. These equations are implemented as a custom material model within a custom FORTRAN onedimensional finite element code. The radial return mapping technique is used with the updated stress vector solved by Newton-Raphson iteration. A consistent tangent stiffness matrix is derived based on the inelastic strain increment. All available experimental data is compared to finite element results to determine the ability of the unified mechanical model to predict deformation, damage evolution, crack growth, and rupture under a creep-fatigue environment.

La première réalisation de ce travail est la construction unifiée et automatique d’un milieu continu équivalent à un treillis de poutres, dans le domaine élastique, en adoptant un modèle de poutres de Bernoulli. Une extension a été réalisée au domaine plastique, selon un algorithme de suivi de la loi de comportement après écrouissage. Suivant l’ordre des développements asymptotiques choisi, on obtient pour le comportement élastique un milieu continu classique ou micropolaire. On se restreint dans ce dernier cas aux treillis à cellules élémentaires centro-symétriques. Les codes de calculs obtenus fournissent de façon automatique les lois de comportement effectives et les modules mécaniques homogénéisés. Une grande variété de treillis, existants ou originaux, a été étudiée. Les résultats ont été systématiquement comparés aux données de la littérature et vérifiés par des simulations éléments finis avec une bonne concordance. La méthode utilisée montre également une capacité à prédire et comprendre le comportement atypique de certains treillis dits auxétiques présentant des coefficients de contraction négatifs. L’homogénéisation dans le domaine plastique a été limitée aux treillis à dominante extensionnelle. Le domaine de résistance élastique a été construit pour différents treillis, et un algorithme d’évolution du comportement avec écrouissage, de type retour-radial a été conçu et implémenté dans un code dédié. Un modèle de poutre élastoplastique à écrouissage isotrope est utilisé. L’application de l’algorithme à une simulation de charge-décharge montre une bonne concordance entre le treillis homogénéisé et les simulations éléments finis / The first achievement of this work is to construct a unified and effective continuum equivalent to a lattice of beams, in the elastic domain, using a Bernoulli beam model. An extension has been done to calculate the elastic domain resistance of such lattices and to build an algorithm for monitoring the constitutive law taking into account work hardening. The choice of the asymptotic expansions leads to a classical continuous or to a micropolar elastic continuum. We restrict in this last case our study to lattices with centro-symmetric unit cells. The numerical codes developed provide the stress-strain relationship and the effective mechanical moduli. A wide variety of trusses has been studied, either existing or original, including typical geometries of foams and various auxetic lattices, exhibiting negative contraction coefficients. The results were systematically compared with data from literature and verified by finite element simulations with a good agreement. The homogenization in the plastic range has been limited to stretching dominated lattices. The equilibrium equations of the discrete asymptotic homogenization have been used to automatically obtain the elastic resistance domain for several trusses, and a return-mapping algorithm for the follow up of the stress-strain relationship including hardening has been conceived and implemented in a dedicated code. An isotropic hardening elastoplastic model of the beam has been used. The application of the algorithm to the simulation of a loading-unloading cycle shows a good agreement between the homogenized lattice and finite element simulations

[pt] Esse trabalho apresenta uma abordagem baseada em programação matemática para a solução de problemas de valor inicial de contorno constitutivo elastoplástico. Considerando a plasticidade associativa, as equações constitutivas locais, em sua forma discreta, são formuladas como problemas de otimização cônica. Especificamente, é demonstrado que métodos implícitos de retorno a superfície para os critérios mais conhecidos da literatura, como o de Rankine, von Mises, Tresca, Drucker-Prager e Mohr Coulomb, podem ser expressos como problemas de otimização cônica de segunda ordem e semidefinida. Além disso, um novo método numérico para a determinação do operador elastoplástico consistente, baseado na derivada paramétrica de primeira ordem das soluções ótimas, é proposto. / [en] This work presents a mathematical programming approach for elastoplastic constitutive initial boundary value problems. Considering associative plasticity, the local discrete constitutive equations are formulated as conic programs. Specifically, it is demonstrated that implicit return-mapping schemes for well-known yield criteria, such as the Rankine, von Mises, Tresca, Drucker-Prager, and Mohr-Coulomb criteria, can be expressed as secondorder and semidefinite conic programs. Additionally, a novel scheme for the numerical evaluation of the consistent elastoplastic tangent operator, based on a first-order parameter derivative of the optimal solutions, is proposed.

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