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.

A series of experiments and finite-element simulations were performed in order to assess existing void coalescence criteria and propose a new model for the coalescence of cylindrical holes in a pure metal matrix during uniaxial stretching. The finite-element simulations were performed so that various plastic limit-load models could be evaluated at each strain increment during deformation, rendering predictions concerning the farfield strains required for coalescence. The experiments were performed in order to identify the actual far-field strain at the moment of incipient coalescence for the specimen geometries considered. The cylindrical-void models of Thomason (1990) and McClintock (1966) outperformed all of the other considered models in their original states. A modified form of the Ragab (2004) plastic limit-load model is proposed in the present work and is shown to have good agreement with the experimental results. The present model accounts for ligament work-hardening and ligament orientation.

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

No description available.

<p>Void growth and coalescence in a single layer model material with holes were visualized by the environmental electron scanning microscope coupled with in situ tensile test. Single sheet model materials were manufactured with a line of laser drilled holes through thickness. In order to investigate the effect of shear localization, the line of holes were oriented with the misorientation angle <em>θ </em>= 0°, 15°, 30°, and 45°. The α-brass samples were studied to introduce the work hardening effect in comparison with the pure copper samples.</p> <p>By taking images at intervals with small strain increments, the void growth behaviors were visualized during the interrupted tensile testing. The void coalescence (defined consistent with Hosokawa et al (2011), as the point at which the voids stopped shrinking laterally) was successfully captured for the first time in the two dimensional studies. The evolutions of void shape change and void rotation during deformation were also studied quantitatively. The results showed that the higher work hardening behaviors can suppress the void coalescence. It also showed that the effect of local volume fraction dominated the coalescence event rather than the void spacing and shear localization. A comparison of the classic models with the experimental results were also made.</p> / Master of Science in Materials Science and Engineering (MSMSE)

The industrial application of high strength steels in structural components has increased the demand on understanding the ductile failure behavior of this type of materials. In practical situations the loading experienced on components made out of these materials can be very complex, which may affect the failure behavior. The objective of this work is to study the effect of stress state on ductile failure and the mechanisms leading to rupture in high strength steels. The stress state is characterized by the stress triaxiality T and the Lode parameter L, which is a deviatoric stress state parameter that discriminates between axisymmetric or shear dominated stress states. For this purpose experiments on two different specimen configurations are performed; a double notched tube (DNT) specimen tested in combined tension and shear and a round notched bar (RNB) specimen tested in uniaxial tension. The two specimens give rise to different stress states at failure in terms of T and L. The failure loci for the DNT specimen show an abrupt change in ductility, indicating a transition between the rupture mechanisms necking of intervoid ligaments and shearing of intervoid ligaments. A clear difference in ductility between the two specimen configurations is also observed, which is closely associated with the difference in stress state at failure. A micromechanical model is developed, which assumes that ductile material failure occurs when the deformation becomes highly non-linear and localizes into a band. The model, which is applied to analyze the experiments, consists of a band with a square array of equally sized cells, with a spherical void located in the center of each cell. The model, extended with a shear criterion, captures the experimental trend rather well. The model also shows that the effect of the deviatoric stress state (L) on void growth, void shape evolution and coalescence is significant, especially at low levels of T and shear dominated stress state. / QC 20100621

Dans le cadre du développement de nuances d’aciers toujours plus performantes en termes de résistance à l’effort et à l’endommagement, les aciers Dual-Phase (DP) présentent un bon compromis résistance/ductilité. Cependant, il est nécessaire de disposer de meilleures connaissances concernant les mécanismes menant à la rupture de tels aciers. Les mécanismes d’endommagement ont ainsi été étudiés dans cette thèse à l’aide de la tomographie aux rayons X. Des essais de traction in-situ ont été réalisés sur plusieurs nuances d’aciers DP, un acier ferritique et un acier martensitique afin de caractériser chaque étape de l’endommagement ductile. Des observations qualitatives et des données quantitatives concernant la germination de l’endommagement, la croissance des cavités et la coalescence ont été recueillies lors de ces essais. Ces données quantitatives ont ensuite été utilisées pour le développement et/ou la validation de modèles d’endommagement. Une prédiction de la cinétique de germination a ainsi été proposée et la version du modèle de croissance de cavités de Rice et Tracey corrigée par Huang et prenant mieux en compte l’effet de la triaxialité a été validée expérimentalement. L’étape de coalescence des cavités menant à la rupture des matériaux a pour la première fois été caractérisée de façon quantitative dans un matériau industriel et des critères de coalescence ont été appliqués localement sur les couples de cavités présentes dans le matériau. L’utilisation de ces modèles analytiques a permis une meilleure compréhension des propriétés agissant sur les phénomènes mis en jeu. L’effet de la part cinématique de l’écrouissage sur la germination et la croissance de l’endommagement a notamment été souligné et validé par des essais de chargements complexes. / As part of the current context of requiring ever more efficient grades of steels in terms of resistance to stress and to damage, the Dual-Phase steels (DP) present an acceptable strength/ductility compromise. It is nevertheless necessary to have a better understanding of the mechanisms leading to the fracture of such steels. Damage mechanisms were studied in this PhD using X-ray tomography. In-situ tensile tests were carried out on several grades of DP steel, a ferritic steel and a martensitic steel in order to characterize each step of ductile damage. Qualitative observations and quantitative data on the nucleation of damage, the void growth and the coalescence of cavities were collected during these tests. This quantitative data was then used for the development and/or the validation of damage models. A prediction of the kinetic of nucleation was proposed and the Huang’s correction of the void growth model of Rice and Tracey accounting for the triaxiality was experimentally validated. For the first time, the step of void coalescence leading to fracture of materials was quantitatively characterized in an industrial material and coalescence criteria were locally applied on couples of neighboring cavities present in the studied specimen. The use of analytical models enabled a better understanding of the properties influencing the studied damage phenomena. The effect of the kinematic part of the strain hardening on void nucleation and void growth was notably emphasized and validated by performing complex loading tests.

The failure mechanism in ductile materials involves void nucleation, their growth and subsequent coalescence to form the fracture surface. The voids are generated due to fracture or debonding of second phase particles or at slip band intersections. The triaxial stress field prevailing around a crack tip and in the necking region strongly influences the growth of these voids. In the initial stages of deformation, these microscale voids are often sufficiently small so that they exist entirely within a single grain of a polycrystalline material. Further, single crystals are used in high technology applications like turbine blades. This motivates the need to study void growth in a single crystal while investigating ductile fracture. Thus, the objectives of this work are to analyze the interaction between a notch tip and void as well as the growth and coalescence of a periodic array of voids under different states of stress in ductile FCC single crystals. First, the growth of a cylindrical void ahead of a notch tip in ductile FCC single crystals is studied. To this end, 2D plane strain finite element simulations are carried out under mode I, small scale yielding conditions, neglecting elastic anisotropy. In most of these computations, the orientation of the FCC single crystal is chosen so that notch lies in the (010) plane, with notch front along the [101] direction and potential crack growth along [101]. This orientation has been frequently observed in experimental studies on fracture of FCC single crystals. Three equivalent slip systems are considered which are deduced by combining three pairs of 3D conjugate slip systems producing only in-plane deformation. Attention is focused on the effects of crystal hardening, ratio of void diameter to spacing from the notch on plastic flow localization in the ligament connecting the notch and the void as well as their growth. The results show strong interaction between slip shear bands emanating from the notch and angular sectors of single slip forming around the void leading to intense plastic strain development in the ligament. However, the ductile fracture processes are retarded by increase in hardening of the single crystal and decrease in ratio of void diameter to spacing from the notch. In order to examine the effect of crystal orientation, computations are performed with an orientation wherein the three effective slip systems are rotated about the normal to the plane of deformation. A strong influence of crystal orientation on near-tip void growth and plastic slip band development is observed. Further, in order to study the synergistic, cooperative growth of multiple voids ahead of the notchtip, an analysis is performed by considering a series of voids located ahead of the tip. It is found that enhanced void growth occurs at higher load levels as compared to the single void model. Next, the growth and coalescence of a periodic array of cylindrical voids in a FCC single crystal is analyzed under different stress states by employing a 2D plane strain, unit cell approach. The orientation of the crystal studied here considers [101] and [010] crystal directions along the minor and major principal stress directions, respectively. Three equivalent slip systems, similar to those in the notch and void simulations are taken into account. Fringe contours of plastic slip and evolution of macroscopic hydrostatic stress and void volume fraction are examined. A criterion for unstable void growth which leads to onset of void coalescence is established. The effects of various stress triaxialities, initial void volume fraction and hardening on void growth and coalescence is assessed. It is observed that plastic slip activity around the void intensifies with increase in stress triaxiality. The macroscopic hydrostatic stress increases with deformation, reaches a peak value and subsequently decreases rapidly. An increase in stress triaxiality enhances the macroscopic hydrostatic stress sustained by the unit cell and promotes void coalescence. The stress triaxiality also has a profound effect on the shape of the void profile. The values of critical void volume fraction and critical strain, which mark onset of void coalescence, decrease within crease in stress triaxiality. However, the onset of void coalescence is delayed by increase in hardening and decrease initial void volume fraction.