The concept of the Forming Limit Diagram (FLD) has proved to be useful for representing conditions for the onset of sheet necking, and is now a standard tool for characterizing materials in terms of their overall forming behavior. In this study, the M-K approach, in conjunction with Gurson model, is used to calculate FLDs. The influences of mechanical properties, including strain hardening, strain rate sensitivity, as well as the void nucleation, growth and coalescence, on the FLDs are examined. Most sheet metals undergo multiple deformation modes (strain paths) when being formed into complex manufacturing parts. When the strain path is changed in the deformation processing of metal, it's work-hardening and flow strength differs from the monotonic deformation characteristics. As a consequence, sheet metal formability is very sensitive to strain path changes. In this study, the hardening behavior and damage evolution under non-proportional loading paths are investigated. The effect of strain path change on FLDs is studied in detail. FLDs are conventionally constructed in strain space and are very sensitive to strain path changes. Alternatively, many researchers represented formability based on the state of stress rather than the state of strain. They constructed a Forming Limit Stress Diagram (FLSD) by plotting the calculated principal stresses at necking. It was concluded that FLSDs were almost path-independent. In this work, the FLSD has been constructed under non-proportional loading conditions to assess its path dependency when damage effect is included. / Thesis / Master of Applied Science (MASc)

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.

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.

Cold rolled aluminum is a widely used metal in industry. The forming limit diagram (FLD) which is commonly used to predict safe deformation parameters currently fails to predict the uniform elongation after non-proportional strain path often found in industrial operations. In this work, a non-proportional strain path change in aluminum alloy 3104 going from plane strain tension to uniaxial tension was investigated. Plane strain tensile tests have been carried out to various pre-strains (3%, 6% and 9%), followed by uniaxial tensile tests at various orientation with respect to the tensile direction (0°, 45° and 90°). Digital image correlation (DIC) was employed to analyze the strain distribution in the sample during deformation. The mechanical response was studied as a function of pre-strain and reloading angle to quantify the effect of strain path change on AA3104.

Stress corrosion cracking (SCC) of alloy 600 is regarded as one of the most important challenges to nuclear power plant operation worldwide. This study investigates two heats of alloy 600 (forged control rod drive mechanismnozzle and rolled divider plate) in order to obtain a better understanding of the effects of the material parameter on the SCC phenomenon. The experimental approach was designed to determine the effect of the manufacturing process (forged vs. rolled), the cold-work (as-received vs. cold-worked) and the strain path (monotonic vs. complex) on SCC of alloy 600. Specimens with different strain paths have been produced from two materials representative of plant components and tested in high temperature (360°C) high pressure primary water environment. The manufacturing process has been proven to have a great effect on the stress corrosion cracking behaviour of alloy 600. Indeed, the SCC susceptibility assessment has demonstrated that the rolled materialis resistant to SCC even after cold work, whereas the forged material is susceptible in the as-received state. Microstructural characterisations have been undertaken to explain these differences in SCC behaviour. The carbide distribution is the main microstructural parameter influencing SCC but the misorientation, in synergy with the carbide distribution, has been proven to give a better representation of the materials SCC susceptibilities.

The ductility of Q&P 1180 steel was studied with regard to retained austenite transformation under different strain paths. Specimens were tested in uniaxial tension in a standard test frame as well as in situ in the scanning electron microscope (SEM). Then digital image correlation (DIC) was used to compute the effective strain at the level of the individual phases in the microstructure. Stretching experiments were also performed using limiting dome height (LDH) tooling, where specimens were strained in both biaxial and plane strain tension. The experiments were done incrementally, for each strain path, and the retained austenite at each level of strain was measured using electron backscatter diffraction (EBSD). Retained austenite levels in the uniaxial tension case dropped from an initial measured level of about 8% to about 2% during an initial strain increment of 0.02, but then stabilized as the specimen was strained to 0.1. In the plane strain and biaxial tension cases retained austenite also dropped significantly during an initial strain increment of about 0.04, but then continued to decrease as the specimens were strained to failure. Biaxial tension, in particular, was the most effective strain path for transforming retained austenite to martensite, resulting in a final volume fraction of 0.3% at an effective strain of 0.3. Retained austenite in the plane-strain tension case dropped at a faster rate than in the biaxial tension case, but finished at about 1% at a strain of 0.1. The greatest limit strains were seen in the biaxial tension case, which may be partly explained by the more effective conversion of retained austenite than was seen in the uniaxial tension case.

Ultra-fine grained (UFG) materials have attracted considerable interest due to the possibility of achieving simultaneous increase in strength and ductility. Effective use of these materials in engineering applications requires investigating the processing-microstructure-property inter-relations leading to a comprehensive understanding of the material behavior. Research efforts on producing UFG hexagonal close packed (hcp) materials have been limited in spite of their envisaged utilization in various technologies. The present study explores multiple UFG hcp materials to identify the general trends in their deformation behaviors, microstructural features, crystallographic texture evolutions and mechanical responses under strain path changes. UFG hcp materials, including commercial purity Ti, Ti-6Al-4V alloy and high purity Zr, were fabricated using equal channel angular extrusion (ECAE) as a severe plastic deformation (SPD) technique following various processing schedules. Several characterization methods and a polycrystal plasticity model were utilized in synergy to impart the relationships between the UFG microstructure, the texture and the post-ECAE flow behavior. Pure UFG hcp materials exhibited enhanced strength properties, making them potential substitutes for coarse-grained high strength expensive alloys. Incorporation of post-ECAE thermo-mechanical treatments was effective in further improvement of the strength and ductility levels. Strong anisotropy of the post-ECAE flow response was evident in all the materials studied. The underlying mechanisms for anisotropy were identified as texture and processing-induced microstructure. Depending on the ECAE route, the applied strain level and the specific material, the relative importance of these two mechanisms on plastic flow anisotropy varied. A viscoplastic self-consistent approach is presented as a reliable model for predicting the texture evolutions and flow behaviors of UFG hcp materials in cases where texture governs the plastic anisotropy. Regardless of the material, the initial billet texture and the extrusion conditions, ECAE of all hcp materials revealed similar texture evolutions. Accurate texture and flow behavior predictions showed that basal slip is the responsible mechanism for such texture evolution in all hcp materials independent of their axial ratio. High strength of the UFG microstructure was presented as a triggering mechanism for the activation of unexpected deformation systems, such as high temperature deformation twinning in Ti-6Al-4V and room temperature basal slip in pure Zr.

Ultra-fine grained (UFG) materials have attracted considerable interest due to the possibility of achieving simultaneous increase in strength and ductility. Effective use of these materials in engineering applications requires investigating the processing-microstructure-property inter-relations leading to a comprehensive understanding of the material behavior. Research efforts on producing UFG hexagonal close packed (hcp) materials have been limited in spite of their envisaged utilization in various technologies. The present study explores multiple UFG hcp materials to identify the general trends in their deformation behaviors, microstructural features, crystallographic texture evolutions and mechanical responses under strain path changes. UFG hcp materials, including commercial purity Ti, Ti-6Al-4V alloy and high purity Zr, were fabricated using equal channel angular extrusion (ECAE) as a severe plastic deformation (SPD) technique following various processing schedules. Several characterization methods and a polycrystal plasticity model were utilized in synergy to impart the relationships between the UFG microstructure, the texture and the post-ECAE flow behavior. Pure UFG hcp materials exhibited enhanced strength properties, making them potential substitutes for coarse-grained high strength expensive alloys. Incorporation of post-ECAE thermo-mechanical treatments was effective in further improvement of the strength and ductility levels. Strong anisotropy of the post-ECAE flow response was evident in all the materials studied. The underlying mechanisms for anisotropy were identified as texture and processing-induced microstructure. Depending on the ECAE route, the applied strain level and the specific material, the relative importance of these two mechanisms on plastic flow anisotropy varied. A viscoplastic self-consistent approach is presented as a reliable model for predicting the texture evolutions and flow behaviors of UFG hcp materials in cases where texture governs the plastic anisotropy. Regardless of the material, the initial billet texture and the extrusion conditions, ECAE of all hcp materials revealed similar texture evolutions. Accurate texture and flow behavior predictions showed that basal slip is the responsible mechanism for such texture evolution in all hcp materials independent of their axial ratio. High strength of the UFG microstructure was presented as a triggering mechanism for the activation of unexpected deformation systems, such as high temperature deformation twinning in Ti-6Al-4V and room temperature basal slip in pure Zr.

This thesis examines the qualitative and quantitative variation in local plastic deformation and surface roughening due to crystallographic texture in body-centered cubic materials, specifically interstitial-free steel sheet and molybdenum foil and sheet. Complex forming operations currently used in industrial manufacturing lead to high material failure rates, due in part to the severity of the applied strain path. A multi-scale model was developed to examine the contribution of mesoscopic and local microscopic behaviour to the macroscopic constitutive response of bcc metals during deformation. The model integrated a dislocation-based hardening scheme and a Taylor-based crystal-plasticity formulation into the subroutine of an explicit dynamic FEM code, LS-DYNA. Numerical analyses using this model were able to predict not only correct grain rotation during deformation, but variations in plastic anisotropy due to initial crystallographic orientation. Simulations of molybdenum foil under uniaxial tension supported the existence of bending due to local variations in plastic anisotropy, confirmed with good quantitative agreement by experimental measurements of surface roughening. A series of two-stage strain-path tests were performed, revealing a prestrain-dependent softening of both the steel and molybdenum samples when an orthogonal secondary strain path is applied. Numerical analyses of these tests overestimate macroscopic hardening during complex loading, due in part to the dynamic nature of the FEM code used. / Thesis (Ph.D, Mechanical and Materials Engineering) -- Queen's University, 2009-04-15 11:51:04.518