La durabilité des composants mécaniques en général et leur résistance à la corrosion en particulier ont une importance primordiale dans l’industrie moderne, qu’elle concerne la production d’énergie, les produits chimiques, le transport, les machines, les matériels médicaux, ou même les composants électroniques. Pour des pièces obtenues par usinage, il est donc nécessaire d’améliorer leur durée de vie et de réduire le risque de défaillance prématurée en améliorant leur intégrité de surface. Ainsi, une compréhension de l’effet du procédé sur l’intégrité de surface induite par usinage et ses conséquences au niveau de sa résistance à la corrosion sont les clés pour relever ces défis.Cette thèse traite le cas particulier de l’usinage de finition du cuivre Cu-c2 et son impact sur la résistance à la corrosion. D’abord, une étude expérimentale comparative du tournage et de la coupe orthogonale est effectuée. Ensuite, vu sa simplicité, la coupe orthogonale fait l’objet de la suite de l’étude. Un modèle numérique est développé pour la prédiction de l’intégrité de surface induite par la coupe. Il utilise une nouvelle loi constitutive du Cu-c2 tenant en compte les transformations microstructurales et l’état des contraintes dans le matériau. Enfin, les résultats issus des études expérimentales ainsi que des simulations numériques concernant l’intégrité de surface sont statistiquement traités dans une analyse multi-physique, dans la perspective d’établir le lien entre la résistance à la corrosion, l’intégrité des surfaces et la physique de la coupe. / The functional performance and life of mechanical components in general and their corrosion resistance in particular are of prime importance in the modern industry, as far as energy production, transportation, machines, medical and even electronic components are concerned. In the case of machined components, it is essential to improve their life and to reduce the premature failure by improving their surface integrity. So, a comprehension of the effect of the machining process mechanics on surface integrity and its consequences on corrosion resistance are essential.This thesis deals with the particular case of finishing machining of oxygen free high conductivity copper (OFHC) and its impact on the surface integrity and corrosion resistance. Firstly, a comparative experimental study between turning and orthogonal cutting is performed. Then, due to its simplicity, orthogonal cutting makes the object of the pursuit of the study. A numerical model is developed to predict the surface integrity induced by the cutting process. It uses a new constitutive model for OFHC copper taking into account microstructural transformations and the state of stress in the work material. Finally, the results issued from experimental studies and the numerical simulations are statistically treated in a multi-physical analysis with the objective of establishing the relationship between corrosion resistance, surface integrity and cutting physics.

The emphasis of this dissertation is on using numerical and plasticity based methods to study two main areas of offshore geotechnics. The first part of this dissertation focuses on the undrained behavior of deeply embedded anchor plates under combined shear and torsion. Plate anchors are increasingly being used instead of typical foundation systems to anchor offshore floating platforms to sustain uplift operating forces. However extreme loading cases would create general loading conditions involving six degrees of freedom. The focus of my research was to evaluate the bearing capacity of plate anchors under two-way horizontal and torsional loading and to study the decreasing effect of torsional moment on the horizontal bearing capacity of these foundations. The study takes advantage of several approaches: Numerical simulation (two and three dimensional finite element analysis) Evaluating and modification of the available plasticity solutions Developing equations for three degree-of-freedom yield locus surfaces The same methodology is applied to evaluate the response of shallow foundations for subsea infrastructure subjected to significant eccentric horizontal loads. The second part of this study focuses on offshore geohazards. Coastal communities and the offshore industry can be impacted directly by geohazards, such as submarine slope failures, or by tsunamis generated by the failed mass movements. This study aims at evaluating the triggering mechanisms of submarine landslide under cyclic wave and earthquake loading. A simple effective stress elasto-plastic model with a minimal number of parameters accounting for monotonic and cyclic response of fine-grained material is developed. The new constitutive soil model could be used to simulate case histories and conduct parametric study to evaluate the effect of slope inclination angle, the earthquake loading with different PGA, frequency content, and duration, as well as various deposition rates to simulate different over pressure levels. This study will generate more insight on the static and cyclic behavior of submarine slopes and influencing factors on their triggering mechanisms using more comprehensive and realistic modeling tools. Several objectives are defined: Developing an appropriate constitutive formulation, Evaluating the constitutive model and material parameters for available databases.

The economical and environmental issues associated with fossil fuels have been urging the automotive industry to cut the fuel consumption and exhaust emission levels, mainly by reducing the weight of vehicles. However, customers increasing demands for safer, more powerful and luxurious vehicles have been adding more weight to the various categories of vehicles, even the smallest ones. Leading car manufacturers have shown that significant weight reduction, yet satisfying the growing demands of customers, would not be feasible without the extensive use of lightweight materials. Magnesium is the lightest constructional metal on earth, offering a great potential for weight-savings. However, magnesium and its alloys exhibit inferior ductility at low temperatures, limiting their practical sheet metal applications. Interestingly, some magnesium alloys exhibit superplastic behaviour at elevated temperatures; mirrored by the extraordinarily large ductility, surpassing that of conventional steels and aluminium alloys. Superplastic forming technique is the process used to form materials of such nature, having the ability to deliver highly-profiled, yet very uniform sheet-metal products, in one single stage. Despite the several attractions, the technique is not widely-used because of a number of issues and obstacles. This study aims at advancing the superplastic forming technique, and offering it as an efficient process for broader utilisation of magnesium alloys for sheet metal applications. The focus is primarily directed to the AZ31 magnesium alloy, since it is commercially available in sheet form, possesses good mechanical properties and high strength/weight ratio. A general multi-axial anisotropic microstructure-based constitutive model that describes the deformation behaviour during superplastic forming is first developed. To calibrate the model for the AZ31 magnesium alloy, systematic uniaxial and biaxial stretching tests are carried out over wide-ranging conditions, using 3 specially-designed fixtures. In a collaborative effort thereafter, the calibrated constitutive model is fed into a FE code in conjunction with a stability criterion, in order to accurately simulate, control and ultimately optimise the superplastic forming process. Special pneumatic bulge forming setup is used to validate some proposed optimisation schemes, by forming sheets into dies of various geometries. Finally, the materials post-superplastic-forming properties are investigated systematically, based on geometrical, mechanical and microstructural measures.

Cette thèse a pour but le développement d'un modèle constitutif hydromécanique prenant en compte le couplage de l'endommagement et de la plasticité dans les géomatériaux non-saturés. Le couplage de ce modèle avec les transferts hydrauliques est rendu possible par son implémentation dans le code aux éléments finis $Theta$-Stock. Un algorithme local a été développé spécifiquement dans ce but. Des problèmes hydromécaniques complètement couplés, tels que la création de la zone endommagée par excavation autour d'un tunnel ou la création d'un endommagement de dessiccation et d'humidification ont été simulés. Une contrainte doublement effective incorporant les effets de la succion et de l'endommagement (considéré isotrope) a été définie en s'appuyant sur des bases thermodynamiques. Cette approche a l'avantage de considérer une unique variable de contrainte étant thermodynamiquement conjuguée aux déformations élastiques. Une formulation hyperélastique dépendante de la pression de confinement est utilisée pour décrire le comportement dans le domaine élastique. L'évolution des rigidités élastiques avec l'endommagement est comparée en considérant deux hypothèses : le principe des déformations équivalentes et le principe de l'énergie élastique équivalente. L'hypothèse d'équivalence des déformations permet d'introduire la contrainte doublement effective dans les équations de plasticité et ainsi de coupler plasticité et endommagement. Les équations de plasticité sont dérivées du modèle de Barcelone (Alonso extit{et al.}, 1990), lui même basé sur le modèle de Cam-Clay. Deux critères distincts d'endommagement et de plasticité sont définis qui peuvent être activés aussi bien indépendamment que simultanément. Les surfaces de charges étant exprimées en fonction de la contrainte effective et de la succion, elles évoluent automatiquement en fonction de la succion et de l'endommagement dans l'espace des contraintes totales. Cela permet de représenter la transition d'un comportement ductile vers un comportement fragile lorsque le matériau est asséché. Un algorithme local explicite a été développé pour gérer le couplage des deux phénomènes dissipatifs. L'implémentation du modèle constitutif dans le code aux éléments finis $Theta$-Stock permet l'étude de problèmes hydromécaniques complètement couplés, les lois de transfert dépendant elles aussi de l'état de saturation du matériau. Ce modèle a d'abord été appliqué à la simulation du développement de micro-fissures lors du séchage d'une éprouvette. L'apparition de l'endommagement est expliquée principalement par le gradient de pression très important créé à la surface de l'échantillon lorsqu'on applique une forte variation de succion. Enfin, un problème à échelle réelle est simulé. L'excavation d'un tunnel, la désaturation du sol environnant dû à la ventilation, ainsi que la création de la zone endommagée par excavation sont étudiés. L'étendue des zones l'endommagement et de déformations plastiques autour du tunnel est étudiée / This thesis work objective is the development of a hydro-mechanical constitutive model which accounts for damage-plasticity couplings in unsaturated geomaterials. The coupling of this model with hydraulic transfers is made possible by its implementation into the Finite Element code Theta-Stock. In order to achieve this implementation, a specific stress-point algorithm has been developed. Fully coupled hydro-mechanical problems have been simulated, such as the creation of the Excavation Damaged Zone around a tunnel and the initiation of damage due to desiccation and humidification. A double effective stress incorporating both the effect of suction and damage (assumed isotropic) is defined based on thermodynamical considerations. The advantage of this approach is that it results in a unique stress variable being thermodynamically conjugated to elastic strains. A pressure-dependent hyperelastic formulation is used to describe the behaviour inside the elastic domain. The evolution of elastic rigidities with damage is then studied. Two hypotheses are compared, the principle of strain equivalence and the principle of equivalent energy. Coupling between damage and plasticity phenomena is achieved by following the principle of strain equivalence and incorporating the effective stress into plasticity equations. The plasticity framework is based on the Barcelona Basic Model (Alonso extit{et al.}, 1990), itself based on the Cam-Clay model. Two distinct criteria are defined for damage and plasticity, which can be activated either independently or simultaneously. Their formulation in terms of effective stress and suction allows them to evolve in the total stress space with suction and damage changes. This leads to a direct coupling between damage and plasticity and allows the model to capture the ductile/brittle behaviour transition occurring when clays are drying. A specific explicit algorithm has been developed to handle the association of the two dissipative phenomena. The implementation of the constitutive model into the Finite Element code Theta-Stock allowed for the simulation of fully coupled hydro-mechanical problems. The hydraulic transfer laws also consider the saturation state. This fully coupled model is first applied to simulate the development of micro-cracks during desiccation of a soil sample. Damage initiation is explained mainly by the important pressure gradient appearing at the boundary when applying a high suction change. Finally, a full-scale problem is simulated. The excavation of a tunnel, the desaturation of the surrounding soil and the creation of the excavation damaged zone are studied

Dans ce travail de thèse, une modélisation multi-échelle est mise en place à partir du concept d’homogénéisation périodique pour étudier le comportement cyclique et dépendant du temps des composites tissés à matrice thermoplastique. Avec l’approche proposée, le comportement macroscopique du composite est déterminé à partir d’une simulation éléments finis effectuée sur une cellule unitaire représentative de la microstructure périodique, où les lois de comportement des constituants sont directement intégrées, à savoir: la matrice et les torons. La réponse locale de la matrice est décrite par une loi de comportement phénoménologique multi-mécanismes intégrant viscoélasticité, viscoplasticité et endommagement ductile. Pour les torons, une loi de comportement hybride micromécanique-phénoménologique est considérée. Cette dernière prend en compte l’endommagement anisotrope et l’anélasticité induite par la présence d’un réseau diffus de microfissures à travers une description micromécanique d’un volume élémentaire représentatif contenant des microfissures. Les capacités du modèle multi-échelles sont validées en comparant les prédictions numériques aux essais expérimentaux. Les capacités du modèle sont également illustrées à travers plusieurs exemples où le composite subit des déformations dépendantes du temps lors de chargements monotones, de chargements à amplitude constante ou cyclique et encore lors de chargement multiaxiaux non proportionnels. En outre, le modèle multi-échelle est aussi utilisé pour analyser l’influence des mécanismes de déformation locaux sur la réponse macroscopique du composite. / In this thesis, a multi-scale model established from the concept of periodic homogenization is utilized to study the cyclic and time-dependent response of thermoplastic-based woven composites. With the proposed approach, the macroscopic behaviour of the composite is determined from a finite element simulation of the representative unit cell of the periodic microstructure, where the local constitutive behaviours of the components are directly integrated, namely: the matrix and the yarns. The local response of the thermoplastic matrix is described by a phenomenological multi-mechanisms constitutive model accounting for viscoelasticity, viscoplasticity and ductile damage. For the yarns, a hybrid micromechanical-phenomenological constitutive model is considered. The latter accounts for anisotropic damage and anelasticity induced by the presence of a diffuse micro-crack network through the micromechanical description of a micro-cracked representative volume element. The capabilities of the multi-scale model are validated by comparing the numerical prediction with experimental data. The capabilities of the model are also illustrated through several examples where the composite undergoes time-dependent deformations under monotonic loading, constant or cyclic stress levels and non-proportional multi-axial loading. Furthermore, the multi-scale model is also employed to analyse the influence of the local deformation processes on the macroscopic response of the composite.

The present study in this thesis has attempted to resolve one of the key aspects of enhancing predictability of macroscopic behavior of Shape Memory Alloy (SMA) wire by considering variation of local phase inhomogeneity. Understanding of functional fatigue and its relation with the phase distribution and its passivation is the key towards tailoring thermal Shape Memory Alloy actuators’ properties and performance. Present work has been carried out in two associated areas. First part has covered solving a coupled thermo-mechanical boundary value problem where initial phase fractions are prescribed at the gauss points and subsequent evolution are tracked over the loading cycle. An incremental form of a phenomenological constitutive model has been incorporated in the modelling framework. Finite element convergence studies using both homogeneous and inhomogeneous SMA wires are performed. Effects of phase inhomogeneity are investigated for mechanical loading and thermo-electric loading. Phase inhomogeneity is simulated mainly due to process and handling quality. An example of mechanical boundary condition such as gripping indicates a negative residual strain at macroscopic behavior. Simulation accurately captures vanishing local phase inhomogeneity upon multiple cycles of thermo-mechanical loading on unconstrained straight SMA wire. In the second part, a phase identification and measurement scheme is proposed. It has been shown that by employing variation of electrical resistivity which distinctly varies with phase transformation, martensite phase volume fraction can be quantified in average sense over the length of a SMA wire. This can be easily achieved by using a simple thermo-mechanical characterization setup along with resistance measurement circuit. Local phase inhomogeneity is created in an experimental sample, which is subjected to electrical heating under constant mechanical bias load. The response shows relaxation of the initial shrinkage strain due to local phase. Results observed for thermo-electric loading on the inhomogeneous SMA wires compliment the results observed from the simulated loading cases. Several interesting features such as shrinkage of the inhomogeneous SMA wire after first loading cycle, relaxation of the residual strain over multiple loading cycles due to the presence of inhomogeneity are captured. This model promises useful applications of SMA wire in fatigue studies, SMA embedded composites and hybrid structures.

Le soudage par point et le collage sont largement utilisés dans la jonction des tôles, telles que l'assemblage de caisses de voiture. Récemment, le soudage par point et le collage ont été combinés pour faire le joint hybride soudé-collé, qui est utilisé pour joindre les aciers à hautes résistances et améliorer la rigidité et la résistance aux chocs des corps de voiture. Dans l'industrie, l'évaluation de la conception avant prototype nécessite des modèles fiables de comportement en termes de prédiction des comportements mécaniques. Le modèle élément finis de joint soudé-collé est un nouveau défi car il doit combiner les modèles de soudage par points et les modèles de collage.Cette thèse se concentre sur la modélisation du joint soudé-collé par de l'acier DP600 et avec l’adhésif structurel SikaPower®-498. La modélisation peur utiliser un modèle solide ou un modèle simplifié (élément coque plus élément de connexion). Le modèle solide permet de prédire le comportement de spécimen à petite échelle: KS2 et cisaillement. Le modèle simplifié peut être utilisé pour prédire la performance des composants de grande dimension avec un coût de calcul acceptable.En ce qui concerne le modèle solide, le comportement du joint soudé et du joint collé sont identifiés séparément calibrés sur un spécimen KS2 sous trajets de chargement différents. Les inhomogénéités dans la zone de fusion et la zone affectée par la chaleur du soudage par point sont prises en compte par l'intermédiaire de facteurs d'échelle applique à la contrainte d'écoulement du métal de base. Les facteurs d'échelle sont determinés par identification inverse. Le modèle de Gurson est utilisé pour prédire la rupture ductile en zone affectée par le chaleur et dans le métal base tandis que le modèle de zone cohésive est utilisé pour simuler la rupture quasi-fragile dans l'interface de la zone de fusion. Les paramètres du modèle de zone cohésive sont identifiés par l'intégrale J à la pointe de fissure de la soudure. Des éléments de zone cohésive avec une loi traction-séparation sont également utilisés pour prédire le décollement adhésif. Les paramètres du modèle sont identifiés par des essais du type « Double Cantilevered Beam » et « End Notched Flexure », correspondant aux mode I et mode II respectivement. Le modèle élaboré pour le soudage par est associé avec le modèle de collage pour prédire le comportement et la rupture du joint soudé-collé.En ce qui concerne le modèle simplifié, des éléments de connexion sont utilisés pour prédire les endommagement des soudure par point. Les paramètres de l'élément de connexion sont identifiés par des tests de KS2 sous différents trajets de chargement. Enfin, les modèles simplifiés d'un soudage, d'un collage, et d'un soudé-collé sont validés sur une jonction en T qui peut représenter le pilier-B de carrosserie de la voiture. / Spot welding and adhesive bonding are widely used in joining of sheet metals, such as assembling of car body-in-white. Recently, spot weld and adhesive are combined to make weld bonded joint, which is employed to join Advanced High Strength Steel to improve the stiffness and crashworthiness of car body. In industry, the assessment of designing prior to prototype requires reliable constitutive models in terms of the prediction of the mechanical behaviors. The FE model of weld bonded joint is a new challenge as it should combine the models of spot welding and the models of adhesive. This thesis focuses on the modeling of weld bonded joint by DP600 steel and structural adhesive SikaPower®-498. The model of weld bonded joint consists of solid model and simplified model. The former is devoted to predict the behavior of weld bonded joint on small-scale specimen: KS2 and lap-shear. The latter can be used to predict the performance of large components with acceptable computational cost. As regards solid model, spot welded joint and adhesive bonded joint behaviors are separately identified by KS2 specimen under different loading path. The inhomogeneities in fusion zone and heat affected zone of spot weld are taken into account via the scaling of the flow stress of base metal. The scaling factors are calibrated by inverse identification. Gurson model is used to predict ductile fracture in heat affected zone and base metal while cohesive zone model is employed to simulate quasi-brittle fracture in the interface of fusion zone. The parameters of cohesive zone model are identified by the J-integral at the notch tip of spot weld crack. Cohesive zone elements with traction-separation-laws are also used to predict adhesive debonding. Model parameters are calibrated by Double Cantilevered Beam and End Notched Flexure specimens, corresponding to Mode-I and Mode-II fracture respectively. The model developed for spot weld is associated with adhesive model to predict weld bonded joint. As regards simplified model, connector elements are employed to predict the damage of spot weld. The parameters of connector element are identified by KS2 tests under different loading paths. Finally, the simplified model of spot welding, adhesive bonding, and weld-bonding are validated by T-joint which can represent the B-pillar of car body.

Constitutive modelling of fibre reinforced solids is the focus of this work. To account for the resulting anisotropy of material, the corresponding strain energy function contains additional terms. Thus, tensile stiffness in the fibre direction is characterised by additional strain invariant and respective material constant. In this way deformation in the fibre direction is penalised. Following this logic, the model investigated in this work includes the term that penalises change in curvature in the fibre direction. The model is based on the large strain anisotropic formulation involving couple stresses, also referred to as “polar elasticity for fibre reinforced solids”. The need of such formulation arises when the size effect becomes significant. Mechanical tests are carried out to confirm the limits of applicability of the classical elasticity for constitutive description of composites with thick fibres. Classical unimaterial models fail to take into account the size affect of fibres and their bending stiffness contribution. The specific simplified model is chosen, which involves new kinematic quantities related to fibre curvature and the corresponding material stiffness parameters. In particular, additional constant k3 (associated with the fibre bending stiffness) is considered. Within the small strains framework, k3 is analytically linked to the geometric and material properties of the composite and can serve as a parameter augmenting the integral stiffness of the whole plate. The numerical tests using the updated finite element code for couple stress theory confirm the relevance of this approach. An analytical study is also carried out, extending the existing solution by Farhat and Soldatos for the fibre-reinforced plate, by including additional extra moduli into constitutive description. Solution for a pure bending problem is extended analytically for couple stress theory. Size effect of fibres is observed analytically. Verification of the new constitutive model and the updated code is carried out using new exact solution for the anisotropic couple stress continuum with the incompressibility constraint. Perfect agreement is achieved for small strain case. Large strain problem is considered by finite element method only qualitatively. Three cases of kinematic constraints on transversely isotropic material are considered in the last section: incompressibility, inextensibility and the double constraint case. They are compared with a general material formulation in which the independent elastic constants are manipulated in order to converge the solution to the “constraint” formulation solution. The problem of a thick plate under sinusoidal load is used as a test problem. The inclusion of couple stresses and additional bending stiffness constant is considered as well. The scheme of determination of the additional constant d31 is suggested by using mechanical tests combined with the analytical procedure.

The research presented in this work addresses open questions regarding (i) the fundamental understanding of powder compaction, and (ii) the complex mechanical response of particle-binder composites under large deformations. This work thus benefits a broad range of industries, from the pharmaceutical industry and its recent efforts on continuous manufacturing of solid tablets, to the defense and energy industries and the recurrent need to predict the performance of energetic materials. Powder compacts and particle-binder composites are essentially confined particulate systems with significant heterogeneity at the meso (particle) scale. While particle mechanics strategies for modeling evolution of mesoscale microstructure during powder compaction depend on the employed contact formulation to accurately predict macroscopic quantities like punch and die wall pressures, modeling of highly nonlinear, strain-path dependent macroscopic response without a distinctive yield surface, typical of particle-binder composites, requires proper constitutive modeling of these complex deformation mechanisms. Moreover, continued loading of particle-binder composites over their operational life may introduce significant undesirable changes to their microstructure and mechanical properties. These challenges are addressed with a combined effort on theoretical, modeling and experimental fronts, namely, (a) novel contact formulations for elasto-plastic particles under high levels of confinement, (b) a multi-scale experimental procedure for assessing changes in microstructure and mechanical behavior of particle-binder composites due to cyclic loading and time-recovery, and (c) a finite strain nonlinear elastic, endochronic plastic constitutive formulation for particle-binder composites.

<p dir="ltr">In structural metallic components, a material’s lifecycle begins with the processing route, to produce a desired structure, which dictates the in-service performance. The variability of microstructural features as a consequence of the processing route has a direct influence on the properties and performance of a material. In order to correlate the influence processing conditions have on material performance, large test matrices are required which tend to be time consuming and expensive. An alternative route to avoid such large test matrices is to incorporate physics-based process modeling and lifing paradigms to better understand the performance of structural materials. By linking microstructural information to the material’s lifecycle, the processing path can be modified without the need to repeat large-scale testing requirements. Additionally, when a materials system is accurately modeled throughout its lifecycle, the performance predictions can be leveraged to improve the design of materials and components.</p><p dir="ltr">Ni-based superalloys are a material class widely used in many critical aerospace components exposed to coupling thermal and mechanical loads due to their increased resistance to creep, corrosion, oxidation, and strength characteristics at elevated temperatures. Many Ni-based superalloys undergo high-temperature forging to produce a desired microstructure, targeting specific strength and fatigue properties in order to perform under thermo-mechanical loads. When in-service, these alloys tend to fail as a consequence of thermo-mechanical fatigue (TMF) from either inclusion- or matrix- driven failure. In order to produce safer, cheaper and more efficient critical aerospace components, the micromechanical deformation and damage mechanisms throughout a Ni-based superalloy’s lifecycle must be understood. This research utilizes process modeling as a tool to understand the damage and deformation of inclusions in a Ni-200 matrix throughout radial forging as a means to optimize the processing conditions for improved fatigue performance. In addition, microstructural sensitive performance modeling for a Ni-based superalloy is leveraged to understand the influence TMF has on damage mechanisms.</p><p dir="ltr">The radial forging processing route requires both high temperatures and large plastic deformation. During this process, non-metallic inclusions (NMIs) can debond from the metallic matrix and break apart, resulting in a linear array of smaller inclusions, known as stringers. The evolution of NMIs into stringers can result in matrix load shedding, localized plasticity, and stress concentrations near the matrix-NMI interface. Due to these factors, stringers can be detrimental to the fatigue life of the final forged component. By performing a finite element model of the forging process with cohesive zones to simulate material debonding, this research contributes to the understanding of processing induced deformation and damage sequences on the onset of stringer formation for Alumina NMIs in a Ni-200 matrix. Through a parametric study, the interactions of forging temperature, strain rate, strain per pass, and interfacial decohesion on the NMI damage evolution metrics are studied, specifically NMI particle separation, rotation, and cavity formation. The parametric study provides a linkage between the various processing conditions parameters influence on detrimental NMI morphology related to material performance.</p><p dir="ltr">The microstructural characteristics of Ni-based superalloys, as a consequence of a particular processing route, creates a variability in TMF performance. The micromechanical failure mechanisms associated with TMF are dependent on various loading parameters, such as temperature, strain range, and strain-temperature phasing. Insights on the complexities of micromechanical TMF damage are studied via a temperature-dependent, dislocation density-based crystal plasticity finite element (CPFE) model with uncertainty quantification. The capabilities of the model’s temperature dependency are examined via direct instantiation and comparison to a high-energy X-ray diffraction microscopy (HEDM) experiment under coupled thermal and mechanical loads. Unique loading states throughout the experiment are investigated with both CPFE predictions and HEDM results to study early indicators of TMF damage mechanisms at the grain scale. The mesoscale validation of the CPFE model to HEDM experimental data provides capabilities for a well-informed TMF performance paradigm under various strain-temperature phase profiles. </p><p dir="ltr">A material’s TMF performance is highly dependent on the temperature-load phase profile as a consequence of path-dependent thermo-mechanical plasticity. To investigate the relationship between microstructural damage and TMF phasing effects, the aforementioned CPFE model investigates in-phase (IP) TMF, out-of-phase (OP) TMF, and iso-thermal (ISO) loading profiles. A microstructural sensitive performance modeling framework with capabilities to isolate phasing (IP, OP, and ISO) effects is presented to locate fatigue damage in a set of statistically equivalent microstructures (SEMs). Location specific plasticity, and grain interactions are studied under the various phasing profiles providing a connection between microstructural material damage and TMF performance.</p>