Industrial metal forming operations generally require several deformation steps in order to create the final product. The mechanical behavior of materials undergoing strain path changes can be very different from those deformed in a given direction to fracture. The work presented here employed laser drilled model materials to better understand the effect of pre-strains and strain path changes on void growth and linkage leading to fracture is studied. The experimental results show that increasing pre-strain results in faster void growth which was justified in terms work hardening rate in the sample. Scanning electron microscope images revealed that the ductility of the sample decreased with increasing pre-strain but only slightly compared to the large decrease in far field strain at failure. This suggests that pre-strain affects strain localization significantly and to a lesser extent the ductility. Finally a finite element model has been built to predict the linkage between voids.

The hot-workability of Titanium (Ti) alloys is of current interest to the aerospace industry due to its widespread application in the design of strong and light-weight aircraft structural components and engine parts. Motivated by the need for accurate simulation of large scale plastic deformation in metals that exhibit macroscopic plastic anisotropy, such as Ti, a constitutive model is developed for anisotropic materials undergoing plastic deformation coupled with ductile damage in the form of internal cavitation. The model is developed from a rigorous micromechanical basis, following well-known previous works in the field. The model incorporates the porosity and void aspect ratio as internal damage variables, and seeks to provide a more accurate prediction of damage growth compared to previous existing models. A closed form expression for the macroscopic yield locus is derived using a Hill-Mandel homogenization and limit analysis of a porous representative volume element. Analytical expressions are also developed for the evolution of the internal variables, porosity and void shape. The developed yield criterion is validated by comparison to numerically determined yield loci for specific anisotropic materials, using a numerical limit analysis technique developed herein. The evolution laws for the internal variables are validated by comparison with direct finite element simulations of porous unit cells. Comparison with previously published results in the literature indicates that the new model yields better agreement with the numerically determined yield loci for a wide range of loading paths. Use of the new model in continuum finite element simulations of ductile fracture may be expected to lead to improved predictions for damage evolution and fracture modes in plastically anisotropic materials.

Industrial metal forming operations generally require several deformation steps in order to create the final product. The mechanical behavior of materials undergoing strain path changes can be very different from those deformed in a given direction to fracture. The work presented here employed laser drilled model materials to better understand the effect of pre-strains and strain path changes on void growth and linkage leading to fracture is studied. The experimental results show that increasing pre-strain results in faster void growth which was justified in terms work hardening rate in the sample. Scanning electron microscope images revealed that the ductility of the sample decreased with increasing pre-strain but only slightly compared to the large decrease in far field strain at failure. This suggests that pre-strain affects strain localization significantly and to a lesser extent the ductility. Finally a finite element model has been built to predict the linkage between voids.

Industrial metal forming operations generally require several deformation steps in order to create the final product. The mechanical behavior of materials undergoing strain path changes can be very different from those deformed in a given direction to fracture. The work presented here employed laser drilled model materials to better understand the effect of pre-strains and strain path changes on void growth and linkage leading to fracture is studied. The experimental results show that increasing pre-strain results in faster void growth which was justified in terms work hardening rate in the sample. Scanning electron microscope images revealed that the ductility of the sample decreased with increasing pre-strain but only slightly compared to the large decrease in far field strain at failure. This suggests that pre-strain affects strain localization significantly and to a lesser extent the ductility. Finally a finite element model has been built to predict the linkage between voids.

A microstructure-based plasticity-damage model is used to predict the mechanical behavior of commercially available AISI 4140 steel. Monotonic tension, compression and torsion tests were performed to obtain the set of plasticity and damage constants required for model calibration. Then, tension tests on Bridgman notched specimens were undertaken to study the damage-triaxiality dependence. Three different notch radii generated different levels of triaxiality at the notch. The modeled triaxiality-damage correlation was validated with SEM fracture surface analysis. Stress-strain correlations under different strain rate and temperature testing conditions were also studied. Little influence of the strain rate was observed. A preliminary study in high-porosity LENS materials was later performed, with satisfactory stress-strain correlation at two different temperatures on tension tests. Finally, a multistage fatigue model was used to predict life in AISI 4140 steel. The goal was to create a baseline for future application of these mathematical models into LENS manufactured materials in component design

A physically motivated Internal State Variable (ISV) constitutive model is extended to account for shear influenced void evolution for predicting damage behavior in ductile solids. The revised ISV model is calibrated for an aluminum 7085-T711 alloy using a series of microstructure and mechanical property quantification experiments. The calibrated ISV model for the aluminum alloy is implemented in an implicit finite-element code (Abaqus) to simulate the deformation of notch Bridgman tension specimens at a variety of stress states and temperatures. The model revisions and calibrated aluminum ISV model are validated through successful prediction of mechanical and microstructure evolution for structures subjected to a variety of complex stress state conditions. The extended ISV model framework is used to study shear influenced plasticity and damage mechanisms resulting from ballistic impact of metals. A Rolled Homogeneous Armor (RHA) steel alloy is selected for the impact model due to wide availability of documented penetration characteristics and ballistic performance data of RHA steel. Finite Element Analysis (FEA) simulations of ballistic impact of rolled homogeneous armor (RHA) steel projectiles against RHA steel plates are performed using a calibrated ISV constitutive model for RHA steel. An FEA simulation based parametric study is performed to assess the effect of a variety of microstructure and mechanical properties on the ballistic performance of RHA steel targets. FEA simulations are used to predict a transition in ballistic perforation mechanisms for high hardness steel alloys by accounting for variations in microstructure properties qualitatively documented in the literature.

Titanium is a widely used metal in industrial and commercial applications. It retains anisotropic mechanical properties at room temperature due to its HCP crystal structure. The effects of crystal orientation have been studied theoretically and through modeling though there is a lack of empirical data available on the topic. The work presented here uses laser-machined voids along with EBSD analysis to study the ductility of grains in different orientations to better understand the microscale fracture process in α-titanium. Experimental results show that hard grains with their c-axis parallel to the tensile direction behave in a less ductile manner than grains with their c-axis oriented away from the tensile direction. This is due to the basal slip systems activating in the former case and prismatic slip systems in the latter. Models utilized include the McClintock model for void growth, Brown-Embury model for void coalescence and FEM crystal plasticity simulations

Titanium is a widely used metal in industrial and commercial applications. It retains anisotropic mechanical properties at room temperature due to its HCP crystal structure. The effects of crystal orientation have been studied theoretically and through modeling though there is a lack of empirical data available on the topic. The work presented here uses laser-machined voids along with EBSD analysis to study the ductility of grains in different orientations to better understand the microscale fracture process in α-titanium. Experimental results show that hard grains with their c-axis parallel to the tensile direction behave in a less ductile manner than grains with their c-axis oriented away from the tensile direction. This is due to the basal slip systems activating in the former case and prismatic slip systems in the latter. Models utilized include the McClintock model for void growth, Brown-Embury model for void coalescence and FEM crystal plasticity simulations

Le mode de rupture des alliages CFC est généralement de type ductile par des mécanismes de germination, croissance et coalescence de cavités internes micrométriques et peut être modifié par l’irradiation. L’irradiation neutronique de ces alliages conduit à la création de défauts cristallins qui induisent un durcissement, une perte de la capacité d’écrouissage, une chute très importante de la ténacité et un mode de déformation localisé à l’échelle intragranulaire. La compréhension des mécanismes physiques élémentaires de la rupture ductile est indispensable au développement de modèles quantitatifs pour prédire la ténacité des matériaux CFC irradiés. Pour cela, trois différents points ont été étudiés dans cette thèse : (1) L’influence de la localisation de la déformation induite par l’irradiation sur la croissance et la coalescence de cavités : des expériences modèles in-situ MEB de croissance et coalescence de cavités micrométriques dans des matériaux irradiés aux protons ont été réalisées. Les résultats montrent un effet limité de la localisation pour des cavités de la taille des grains et une diminution de l’influence de la localisation avec l’augmentation du niveau de déformation pour des cavités intragranulaires. Par conséquent, les modèles homogénéisés de matériaux poreux développés pour les matériaux non irradiés pourraientt être utilisés en première approximation pour modéliser la rupture ductile des matériaux irradiés. (2) Le comportement sous chargement mécanique de nano-porosités d’irradiation et leur contribution éventuelle à la rupture : l’étude expérimentale et numérique de la déformation de cavités dans un matériau nanoporeux a permis de mettre en évidence la très forte hétérogénéité de la déformation à cette échelle et l’absence d’effet de taille significatif sur la déformation des cavités de diamètre supérieur à 10 nm en traction simple. (3) Le développement de modèles homogénéisés de matériaux poreux valides aux fortes porosités : deux nouveaux critères de coalescence obtenus par analyse limite sont proposés et validés par comparaison à des simulations d’analyses limites numériques, dans le cas de cavités de type fissures et de cavités ellipsoïdales. / The failure mode of FCC alloys is generally ductile through nucleation, growth and coalescence of micrometric voids, and can be modified by irradiation. Neutron irradiation of these alloys leads to the creation of crystalline defects that induce hardening, loss of work hardening capability, a very large drop in fracture toughness and a heterogeneous deformation mode at the grain scale. Understanding the elementary physical mechanisms of ductile fracture is essential for the development of quantitative models to predict fracture toughness of irradiated FCC materials. Thus, in this thesis, three different subjects have been studied. (1) Influence of the localization of deformation induced by irradiation on void growth and coalescence: Model experiments of growth and coalescence of micrometric voids in proton-irradiated materials have been performed based on SEM in-situ tests. Results show a limited effect of localization for grain-size voids and a decreasing influence of localization with increasing level of deformation for intragranular voids, so that homogenized models of porous materials developed for unirradiated materials may be used as a first approximation to model the ductile fracture of irradiated materials. (2) The behavior under mechanical loading of nanovoids generated under irradiation and their possible contribution to fracture: The experimental and numerical study of void deformation in a nanoporous material highlights the very strong heterogeneity of the deformation at this scale and the absence of significant size effect for voids of diameter greater than 10 nm under tensile loading. (3) Development of homogenized models for porous materials valid at high porosities: Two new coalescence criteria obtained by limit analysis are proposed and validated by comparison with numerical limit analysis simulations, in the case of penny-shaped cracks and ellipsoidal voids.

abstract: As the microelectronics industry continues to decrease the size of solder joints, each joint will have to carry a greater current density, making atom diffusion due to current flow, electromigration (EM), a problem of ever-increasing severity. The rate of EM damage depends on current density, operating temperature, and the original microstructure of the solder joint, including void volume, grain orientation, and grain size. While numerous studies have investigated the post-mortem effects of EM and have tested a range of current densities and temperatures, none have been able to analyze how the same joint evolves from its initial to final microstructure. This thesis focuses on the study of EM, thermal aging, and thermal cycling in Sn-rich solder joints. Solder joints were either of controlled microstructure and orientation or had trace alloying element additions. Sn grain orientation has been linked to a solder joints’ susceptibility to EM damage, but the precise relationship between orientation and intermetallic (IMC) and void growth has not been deduced. In this research x-ray microtomography was used to nondestructively scan samples and generate 3D reconstructions of both surface and internal features such as interfaces, IMC particles, and voids within a solder joint. Combined with controlled fabrication techniques to create comparable samples and electron backscatter diffraction (EBSD) and energy-dispersive spectroscopy (EDS) analysis for grain orientation and composition analysis, this work shows how grain structure plays a critical role in EM damage and how it differs from damage accrued from thermal effects that occur simultaneously. Unique IMC growth and voiding behaviors are characterized and explained in relation to the solder microstructures that cause their formation and the possible IMC-suppression effects of trace alloying element addition are discussed. / Dissertation/Thesis / Doctoral Dissertation Materials Science and Engineering 2019