原位TiB_(2)颗粒增强7075铝基复合材料在不同应力状态下的韧性断裂行为

采用力学试验、微观表征和数值模拟研究原位TiB_(2)颗粒增强7075铝基复合材料在不同应力状态下的断裂行为。设计4组拉伸试样、1组剪切试样和1组压缩试样,并对这6组试样进行力学实验。通过原位应变测试和有限元模拟研究6组试样在变形过程中的应变分布。对6组试样的断口形貌进行表征,分析其在不同应力状态下的损伤演化机制。研究发现:该材料的主要断裂机制为界面脱粘和颗粒断裂,表现为高应力三轴度下的拉伸断裂和低应力三轴度下的剪切断裂。在拉伸断裂条件下,形核空洞的体积在最大主应力的作用下增大;在剪切断裂条件下,空洞的形状在最大剪应力作用下变化明显,而体积变化不明显。基于实验揭示的断裂机理,提出一种考虑最大主应力和最大剪应力的韧性断裂准则,该准则可以预测该复合材料在不同应力状态下的断裂曲面。与改进的Mohr−Coulomb、Lou−Yoon−Huh、Hu和Mu模型的对比分析表明,新模型能更准确地预测铝基复合材料的韧性断裂行为。

原位TiB_(2)颗粒增强7075铝基复合材料的热压缩变形行为和显微组织演变

采用等温热压缩实验研究不同变形条件下(变形温度300~450℃、应变速率0.001~1 s^(−1))原位TiB_(2)颗粒增强7075铝基复合材料的热成形行为、损伤机制和显微组织演变。结果表明,复合材料在低温和高应变速率下的主要损伤机制是颗粒断裂和界面脱粘,而在高温和低应变速率下主要是基体的韧窝断裂。此外,复合材料在高温、低应变速率变形条件下(变形温度450℃、应变速率0.001 s^(−1))出现完全动态再结晶,从而提高复合材料的热成形性。热压缩后原位TiB_(2)/7075Al复合材料的晶粒尺寸明显小于7075Al和非原位7075Al复合材料。根据流动应力实验曲线,建立原位TiB_(2)/7075Al复合材料包含流变应力、真应变、应变速率和温度的本构方程。基于动态材料模型(DMM)和改进的动态材料模型(MDMM)建立加工图,分析复合材料的流变失稳区和优化复合材料的热变形工艺参数。复合材料的最佳变形条件为变形温度425~450℃、应变速率0.001~0.01 s^(−1),在该变形条件下复合材料的晶粒得到细化,且不发生颗粒断裂和界面脱粘。

Numerical Simulation of Microstructure Evolution for SA508-3 Steel during Inhomogeneous Hot Deformation Process

Based on hot compression tests by a Gleeble-1500D thermo-mechanical simulator, the flow stress model and microstructure evolution model for SA508-3 steel were established through the classical theories on work hardening and softening. The developed models were integrated into 3D thermal-mechanical coupled rigid plastic finite element software DEFORM3D. The inhomogeneous hot deformation （IHD） experiments of SA508 3 steel were designed and carried out. Meanwhile, numerical simulation was implemented to investigate the effect of temperature, strain and strain rate on microstructure during IHD process through measuring grain sizes at given positions. The simulated grain sizes were basically in agreement with the experimental ones. The results of experiment and simulation demonstrated that temperature is the main factor for the initiation of dynamic recrystallization （DRX）, and higher temperature means lower critical strain so that DRX can be facilitated to obtain uniform fine microstructure.

3D processing map for hot working of extruded AZ80 magnesium alloy

The hot deformation behavior of extruded AZ80 magnesium alloy was investigated using compression tests in the temperature range of 250–400 °C and strain rate range of 0.001–1.000 s–1. The 3D power dissipation map was developed to evaluate the hot deformation mechanisms and determine the optimal processing parameters. Two domains of dynamic recrystallization were identified from the 3D power dissipation map, with one occurring in the temperature and strain rate range of 250–320 °C and 0.001–0.010 s–1and the other one occurring in the temperature and strain rate range of 380–400 °C and 0.001–0.003 s–1. In order to delineate the regions of flow instability, Prasad’s instability criterion, Murty’s instability criterion and Gegel’s stability criteria were employed to develop the 3D instability maps. Through microstructural examination, it is found that Prasad’s and Murty’s instability criteria are more effective than Gegel’s stability criteria in predicting the flow instability regions for extruded AZ80 alloy. Further, the 3D processing maps were integrated into finite element simulation and the predictions of the simulation are in good agreement with the experimental results.

A 2.5-dimensional Analytical Model of Cold Leveling for Plates with Transverse Wave Defects

Waves occurring in cold-rolled plates or sheets can be divided into longitudinal and transverse waves. Classical leveling theories merely solve the problem of longitudinal waves, while no well accepted method can be employed for transverse waves. In order to investigate the essential deformation law of leveling for plates with transverse waves, a 2.5-dimensional （2.5- D） analytical approach was proposed. In this model, the plate was transversely divided into some strips with equal width; the strips are considered to be in the state of plane strain and each group of adjacent strips are assumed to be deformation compatible under stress. After calculation, the bending deformation of each strip and the leveling effect of overall plate were obtained by comprehensNe consideration of various strips along with the width. Bending of roller is a main approach to eliminate the transverse waves, which is widely accepted by the industry, but the essential effect of bending of roller on the deformation of plates and the calculation of bending of roller are unknown. According to the 2.5-D analytical model, it can be found that, for plates, it is neutral plane offsetting and middle plane elongation or contraction under inner stress that can effectively improve plate shape. Taking double side waves as an example, the appropriate values of bending of roller were obtained by the 2.5-D analytical model related to different initial unevenness, which was applicable to the current on-line adjusting of bending of roller in rolling industry.

Effects of process parameters on fragment and refinement of millimeter- grade coarse grains for 316LN steel during hot cogging

The heterogeneous mixed-grain microstructure is a common defect for the heavy forging of 316LN austenitie stainless steel. Isothermal compression experiments were performed on a Gleeble-3500 thermo-mechanical simulator to investigate the effect of process parameters on the fragment and re- finement of millimeter-grade coarse grains （MCGs） during hot cogging. The experimental results in- dicate that the stress of MCG specimens is much larger than that of fine grain （FG） ones at 1150 ℃, while the stress difference between MCG and FG samples became smaller at 1200 ℃. Moreover, the MCGs can be well fragmented and refined under the condition of temperature of 1200 ℃, strain rate of 0.01 s-1 , and reduction rate of 50%. Meanwhile, numerical simulations were conducted to study the influences of temperature, strain and strain rate on microstructure evolution. The results of ex- periments and simulations comprehensively demonstrate that the MCG results in the increase of de- formation resistance and incompatibility of deformation, and it can be fragmented and refined at 1200 ℃ so that the plastic deformation energy decreases remarkably with the increase of temperature from 1 150 to 1200 ℃.

Ductile Fracture Prediction of 316LN Stainless Steel in Hot Deformation Process

A ductile fracture criterion of 316LN stainless steel, combined with the plastic deformation capacity of ma- terial and the stress state dependent damages, was proposed to predict ductile fracture during hot deformation. To the end, tensile tests at high temperatures were first performed to investigate the fracture behavior of 316LN stain- less steel. The experimental results show the variation of the critical fracture strain as a function of temperature and strain rate. Second, the criterion was calibrated by using the upsetting tests and the corresponding numerical simula- tions. Finally, the proposed fracture criterion was validated by the designed tests and the corresponding finite ele- ment （FE） simulation. The results show that the criterion can successfully predict the onset of ductile fracture at ele- vated temperatures.

Controlling Flow Instability in Straight Spur Gear Forging Using Numerical Simulation and Response Surface Method

Workability domain without the onset of flow instability was developed by numerical simulation and response surface method （RSM） for complex-shaped straight spur gear forging. The processing map of AZ31B alloys was calculated from flow stress curves and then integrated with the finite element model to simulate the distribution of flow instability in the straight spur gear undergoing isothermal forging process. Occurrence of flow instability depends on forging temperature, punch velocity and billet reduction. Taking forging temperature and punch velocity as design variables, while billet reduction as response variable, RSM of workability domain was established. Analysis of variance indicates that forging temperature is the most significant factor determining the appearance of flow instability in the forged gear. Flow instability is easier to take place at lower temperatures of 250 and 300 ℃ in the early stage of forging but at higher temperatures of 350 and 400 ℃ in the later stage of forging, which is attributed to different deformation mechanisms and dynamic recrystallization behaviors at different temperatures or deformation levels. Meanwhile, increasing punch velocity further reduces the workability of the forged gear. Four different processing paths were chosen to carry out the gear forging trials. Visual observations and metallographic examinations demonstrate that the developed workability domain contributes to optimization of forging parameters.

Microstructure and properties of high-strength Cu–Ni–Si–(Ti) alloys

The tradeoff between the strength and the fracture elongation in the high-strength Cu-Ni-Si alloy became a hot research topic recently.Cu-Ni-Si-(Ti) alloys were fabricated in a vacuum induction melting furnace to study the effects of titanium on the microstructure and mechanical properties of Cu-Ni-Si alloys with different thermo-mechanical treatments.After homogenization at 900℃ for 4 h,hot-rolled by 80%,solution treatment at 970℃ for 2 h,cold-rolled by 50%,and finally aged at 450℃ for 180 min,the studied Cu-10 Ni-Si-2 Ti alloy achieved the hardness of HV 252.4,electrical conductivity of 23.6% IACS,tensile strength of 764.4 MPa,yield strength of 622.26 MPa,fracture elongation of 10.4%,and strength-elongation product of 7.95 GPa%,which are less than those of the studied Cu-10 Ni-2 Si alloy.The addition of Ti contributed to refining the microstructure,suppressing the decreasing trend in mechanical properties after peak hardening,and arousing a primary substructure strengthening mechanism rather than the precipitation strengthening in Cu-Ni-Si alloys.These findings provide essential understandings of the effects of the Ti on Cu-Ni-Si system alloys,and the designed Cu-Ni-Si alloys with highstrength and fracture elongation could fulfill some requirements of the electronic and electrical industry.

Static Recrystallization Behavior of SA508-III Steel during Hot Deformation

The static recrystallization behavior of SA508-III steel was investigated by isothermal double-hit hot compression tests at the deformation temperature of 950-1 250 ℃,the strain rate of 0. 01-1 s^（-1）,and the inter-pass time of 1-300 s.The effects of deformation parameters,including forming temperature,strain rate,degree of deformation（ pre-strain） and initial austenite grain size,on the softening kinetics were analyzed. Experimental results show that static recrystallization kinetics is strongly dependent on deformation temperature and degree of deformation,while less affected by the strain rate and initial grain size. The kinetics and microstructural evolution equations of static recrystallization for SA508-III steel were developed to predict the softening behavior and the statically recrystallized grain size,respectively. Based on the comparison between the experimental and predicted results,it is found that the established equations can give a reasonable estimate of the static softening behavior for SA508-III steel.

Modified artificial neural network model with an explicit expression to describe flow behavior and processing maps of Ti2AlNb-based superalloy

The elevated-temperature deformation behavior of Ti2AlNb superalloy was observed by isothermal compression experiments in a wide range of temperatures(950–1200°C)and strain rates(0.001–10 s^(-1)).The flow behavior is nonlinear,strongly coupled,and multivariable.The constitutive models,namely the double multivariate nonlinear regression model,artificial neural network model,and modified artificial neural network model with an explicit expression,were applied to describe the Ti2AlNb superalloy plastic deformation behavior.The comparative predictability of those constitutive models was further evaluated by considering the correlation coefficient and average absolute relative error.The comparative results show that the modified artificial network model can describe the flow stress of Ti2AlNb superalloy more accurately than the other developed constitutive models.The explicit expression obtained from the modified artificial neural network model can be directly used for finite element simulation.The modified artificial neural network model solves the problems that the double multivariate nonlinear regression model cannot describe the nonlinear,strongly coupled,and multivariable flow behavior of Ti2AlNb superalloy accurately,and the artificial neural network model cannot be embedded into the finite element software directly.However,the modified artificial neural network model is mainly dependent on the quantity of high-quality experimental data and characteristic variables,and the modified artificial neural network model has not physical meanings.Besides,the processing maps were applied to obtain the optimum processing parameters.

Hot Deformation Stability of Extruded AZ61 Magnesium Alloy Using Different Instability Criteria

The hot deformation stability of extruded AZ61 magnesium alloy was investigated by means of hot com- pression tests at the temperature range of 250-400 ℃ and strain rate range of 0.001-1 s^-1. The 3D instability maps considering the effect of strain were developed to delineate the regions of unstable flow on the basis of Jonas＇s, Semiatin＇s, Prasad＇s, Murty＇ s, Gegel＇s and Alexander＇s criteria. Since non-uniform deformation occurs due to the initial microstructure inhomogeneity, the friction, etc., finite element simulations were performed to determine the position of the specimens which can mostly represent the preset deformation parameter. Detailed microstructural investigation on such position was carried out to examine the validity of the instability maps, and the results indicate that for extruded AZ61 magnesium alloy： （1） Jonas＇s and Semiatin＇s criteria conservatively predict the instability regions; （2） Gegel＇s and Alexander＇s criteria inadequately predict the instability regions; （3） Prasad＇s and Murty＇s criteria provide more effective predictions of the instability regions than Jonas＇s, Semiatin＇s, Gegel＇s and Alexander＇s criteria,

Constitutive Modeling for Elevated Temperature Flow Behavior of30Cr2Ni4MoV Ultra-super-critical Rotor Steel

In order to perform numerical simulation of forging and determine the hot deformation processing parameters for 30Cr2Ni4MoV steel, the compressive deformation behaviors of 30Cr2Ni4MoV steel were investigated at the temperatures from 970 to 1270 ℃ and strain rates from 0. 001 to 0.1 s-1 on a Gleeble-3500 thermo-mechanical simulator. The flow stress constitutive equations of the work hardening-dynamical recovery period and dynamical recrystallization period were established for 30Cr2Ni4MoV steel. The stress-strain curves of 30Cr2Ni4MoV steel predicted by the proposed model well agreed with experimental results, which confirmed that the proposed equations can be used to determine the hot deformation processing parameters for 30Cr2Ni4MoV steel.