Modeling asymmetric fracture mechanics of Mg alloy wire in drawing process

In this study,a numerical analysis was conducted on the ductile fracture of a 2-mm diameter Mg-1Zn-0.5Mn-0.5Sr-0.1Ca alloy wire during drawing.The hexagonally close-packed crystal structure of Mg alloys causes asymmetric fracture behavior,especially in the compression region.The aim of this study is to develop a comprehensive damage model for Mg alloy wire that accurately predicts ductile fracture,with a focus on the compression region.A novel experimental method was introduced to measure the ductile fracture of Mg alloy wires under different stress states.The wire drawing process was simulated using the Generalized Incremental Stress-State dependent damage(GISSMO)Model and the Semi-Analytical Model for Polymers(SAMP)model.The damage model's prediction and the experimental results were found to be in excellent agreement,especially in determining crack initiation.Computational analysis established a safe zone diagram for die angle and reduction ratio,and experimental validation confirmed the feasibility of this approach.The proposed damage model can provide a practical and reliable analysis for optimizing the drawing process of Mg alloy wire.

Study on hot deformation behavior of homogenized Mg-8.5Gd-4.5Y-0.8Zn-0.4Zr alloy using a combination of strain-compensated Arrhenius constitutive model and finite element simulation method

Isothermal hot compression experiments were conducted on homogenized Mg-8.5Gd-4.5Y-0.8Zn-0.4Zr alloy to investigate hot deformation behavior at the temperature range of 673-773 K and the strain rate range of 0.001-1 s^(-1)by using a Gleeble-1500D thermo mechanical simulator.Metallographic characterization on samples deformed to true strain of 0.70 illustrates the occurrence of flow localization and/or microcrack at deformation conditions of 673 K/0.01 s^(-1),673 K/1 s^(-1)and 698 K/1 s^(-1),indicating that these three deformation conditions should be excluded during hot working of homogenized Mg-8.5Gd-4.5Y-0.8Zn-0.4Zr alloy.Based on the measured true stress-strain data,the strain-compensated Arrhenius constitutive model was constructed and then incorporated into UHARD subroutine of ABAQUS software to study hot deformation process of homogenized Mg-8.5Gd-4.5Y-0.8Zn-0.4Zr alloy.By comparison with measured force-displacement curves,the predicted results can describe well the rheological behavior of homogenized Mg-8.5Gd-4.5Y-0.8Zn-0.4Zr alloy,verifying the validity of finite element simulation of hot compression process with this complicated constitutive model.Numerical results demonstrate that the distribution of values of material parameters(α,n,Q and ln A)within deformed sample is inhomogeneous.This issue is directly correlated to the uneven distribution of equivalent plastic strain due to the friction effect.Moreover,at a given temperature the increase of strain rate would result in the decrease of equivalent plastic strain within the central region of deformed sample,which hinders the occurrence of dynamic recrystallization(DRX).

A novel Ti-5.55Al-6.70Zr-1.50V-0.70Mo-3.41Nb-0.21Si alloy designed using cluster-plus-glue-atom model for laser additive manufacturing

A novel Ti-5.55Al-6.70Zr-1.50V-0.70Mo-3.41Nb-0.21Si alloy was designed using the cluster formula approach(cluster-plus-glue-atom model)and prepared by laser melting deposition(LMD).Its composition formula 12[Al-Ti_(12)](AlTi_(2))+5[Al_(0.8)Si_(0.2)-Ti_(12)Zr_(2)](V_(0.8)Mo_(0.2)Nb_(1)Ti)features an enhancedβ-Ti via co-alloying of Zr,V,Mo,Nb and Si.The experimental results show that the cluster formula ofαandβphases in the novel alloy are respectivelyα-[Al-Ti_(11.5)Zr_(0.5)](Al_(1)Ti_(2))andβ-[Al_(0.8)Si_(0.2)-Ti_(13.2)Zr_(0.8)](V_(1)Mo_(0.4)Nb_(1.6)),both containing Zr elements.The fitted composition via the α andβphase cluster formulas has little difference with the actual alloy composition,suggesting that the validity of cluster-plus-glue-atom model in the alloy composition design.After hot isostatic pressing(HIP),both the Ti-6Al-4V and the novel alloy by LMD are characterized by prior-βcolumnar grains,while the typical<100>texture disappears.Compared with Ti-6Al-4V,Ti-5.55Al-6.70Zr-1.50V-0.70Mo-3.41Nb-0.21Si alloy exhibits a combination of higher strength(1,056 MPa)and higher ductility(14%)at room temperature and higher strength(580 MPa)at 550℃ after HIP,and can potentially serves as LMD materials.

Study on Dynamic Mechanical Behavior of Al-Mg-Si Alloy

The dynamic mechanical behavior of Al-Mg-Si alloy was investigated under different strain rates by mechanical property and microstructure characterization,constitutive behavior analysis and numerical simulation in the present study.As the strain rate increases,the yield strength,ultimate tensile strength and elongation increase first,then remain almost constant,and finally increase.The alloy always exhibits a typical ductile fracture mode,not depending on the strain rate.However,as the strain rate increases,the number of dimples gradually increases.Tensile deformation can refine grains,however,the grain structure is slightly affected by the strain rate.An optimized Johnson-Cook constitutive equation was used to describe the mechanical behavior and obtained by fitting the true stress-strain curves.The parameter C was described by a function related to the strain rate.The fitting true stress-strain curves by the JC model agree very well with the experimental true stress-strain curves.The true stress-strain curves calculated by the finite element numerical simulation agree well with the experimental true stress-strain curves.

Low-cycle fatigue behavior of solutionized and aged WE43 magnesium alloys at room temperature

The low-cycle fatigue behavior of solutionized(T4)and aged(T6)WE43 magnesium alloys was studied at room temperature.The total strain amplitudes(△ε_(t)/2)were 0.4%,0.5%,0.6%,0.7%and 1.0%.Detailed microstructure evolution was characterized by scanning electron microscope(SEM),electron backscattered diffraction(EBSD)and transmission electron microscopy(TEM).The results showed that plastic strain amplitude decreased with the increasing cycle number in T4 alloy,which is due to the dense persistent slip bands(PSBs)and dynamic precipitates hinderingdislocation slip.In contrast,the plastic strain amplitude increases gradually in T6 alloy,which is attributed to the enhanced activation of pyramidal slip.The low-cycle fatigue life of T6 alloy with larger fatigue ductility coefficient is longer than that of T4 alloy.The Coffin-Manson model can accurately predict the fatigue life of T4 and T6 alloys compared to Jahed-Varvani(JV)energy model.For T4 alloy,the fatigue damage mechanism was dominated by basal slip.For T6 alloy,the enhanced pyramidal slip plays an important role to accommodate plastic deformation.

In-situ Micro-CT analysis of deformation behavior in sandwich-structured meta-stable beta Ti−35Nb alloy

Beta Ti−35Nb sandwich-structured composites with various reinforcing layers were designed and produced using additive manufacturing(AM)to achieve a balance between light weight and high strength.The impact of reinforcing layers on the compressive deformation behavior of porous composites was investigated through micro-computed tomography(Micro-CT)and finite element method(FEM)analyses.The results indicate that the addition of reinforcement layers to sandwich structures can significantly enhance the compressive yield strength and energy absorption capacity of porous metal structures;Micro-CT in-situ observation shows that the strain of the porous structure without the reinforcing layer is concentrated in the middle region,while the strain of the porous structure with the reinforcing layer is uniformly distributed;FEM analysis reveals that the reinforcing layers can alter stress distribution and reduce stress concentration,thereby promoting uniform deformation of the porous structure.The addition of reinforcing layer increases the compressive yield strength of sandwich-structured composite materials by 124%under the condition of limited reduction of porosity,and the yield strength increases from 4.6 to 10.3 MPa.

Effect of pre-deformation on aging creep of Al-Li-S4 alloy and its constitutive modeling

A set of uniaxial tensile creep tests at different pre-deformations, aging temperatures and stress levels were carried out for Al-Li-S4 alloy, and the creep behavior and the effects of pre-deformation on mechanical properties and microstructures were determined under basic thermodynamics conditions of aging forming. The results show that pre-deformation shortens the time of primary creep and raises the second steady-state creep rate. Then, the total creep strain is greater, but in the range of test parameters it is still smaller than that without pre-deformation. In addition, transmission electron microscopy（TEM） observation shows that pre-deformation promotes the formation of T1 phase and θ′ phase and makes them distribute more dispersively, while inhibits the generation of δ′ phase, which leads to the improvement of mechanical properties of the alloy. A unified constitutive model reflecting the effects of aging mechanism, stress levels and different pre-deformations was established. The fitting results agree with the experimental data well.

Arrhenius-type constitutive model and dynamic recrystallization behavior of V-5Cr-5Ti alloy during hot compression

To clarify the high temperature flow stress behavior and microstructures evolution of a V-5Cr-5Ti （mass fraction, %） alloy, the isothermal hot compression tests were conducted in the temperature range of 1423-1573 K with strain rates of 0.01, 0.1, and 1 s-1. The results show that the measured flow stress should be revised by friction and the calculated values of friction coefficient m are in the range of 0.45-0.56. Arrhenius-type constitutive equation was developed by regression analysis. The comparison between the experimental and predicted flow stress shows that the R~ and the average absolute relative error （AARE） are 0.948 and 5.44%, respectively. The measured apparent activation energy Qa is in the range of 540-890 kJ/mol. Both dis-continuous dynamic recrystallization （DDRX） and continuous dynamic recrystallization （CDRX） mechanisms are observed in the deformed alloy, but dynamic recovery （DRV） is the dominant softening mechanism up to a true strain of 1.5.

Improvement and application of neural network models in development of wrought magnesium alloys

Neural network models of mechanical properties prediction for wrought magnesium alloys were improved by using more reasonable parameters, and were used to develop new types of magnesium alloys. The parameters were confirmed by comparing prediction errors and correlation coefficients of models, which have been built with all the parameters used commonly with training of all permutations and combinations. The application was focused on Mg-Zn-Mn and Mg-Zn-Y-Zr alloys. The prediction of mechanical properties of Mg-Zn-Mn alloys and the effects of mole ratios of Y to Zn on the strengths in Mg-Zn-Y-Zr alloys were investigated by using the improved models. The predicted results are good agreement with the experimental values. A high strength extruded Mg-Zn-Zr-Y alloy was also developed by the models. The applications of the models indicate that the improved models can be used to develop new types of wrought magnesium alloys.

Deformation behavior and constitutive model for dual-phase Mg-Li alloy at elevated temperatures

In order to study the deformation behavior and evaluate the workability of the dual-phase Mg-9Li-3Al-2Sr alloy, isothermal hot compression tests were conducted using the Gleeble-3500 thermal-mechanical simulator, in ranges of elevated temperatures （423-573 K） and strain rates （0.001-1 s^-1）. Plastic instability is evident during the deformation which is in the form of serrated flow; serrated yielding is attributed to the locking of mobile dislocations by the Mg and Li atoms which diffuse during the deformation. The relationships between flow stress, strain rate and deformation temperature were analyzed and the deformation activation energy and some basic material factors at different strains were calculated using the Arrhenius equation. The effects of temperature and strain rate on deformation behavior were represented using the Zener–Hollomon parameter in an exponent-type equation. To verify the validity of the constitutive model, the predicted values and experimental flow curves under different deformation conditions were compared, the correlation coefficient （0.9970） and average absolute relative error （AARE=4.41%） were calculated. The results indicate that the constitutive model can be used to accurately predict the flow behavior of dual-phase Mg-9Li-3Al-2Sr alloy during high temperature deformation.

Application of molecular interaction volume model in separation of Pb-Sn-Sb ternary alloy by vacuum distillation

Based on the molecular interaction volume model （MIVM）, the activities of components of Pb Sn Sb ternary alloy were predicted. The vapo^liquid phase equilibrium of Pb-Sn-Sb alloy system was calculated using the activity coefficients of Pb Sn-Sb alloy system in the process of vacuum distillation. The calculated results show that the content of Sn in vapor phase increases with the increasing distillation temperature and content of Sn in liquid phase. However, the content of Sn in vapor phase is only 0.45% （mass fraction） while 97% in liquid phase at 1100 ℃, which shows that the separating effect is very well. Experimental investigations on the separation of Pb-Sn-Sb ternary alloy were carried out in the distillation temperature range of 1100-1300 ℃ under vacuum condition. It is found that the Sn content in vapor phase is 0.54% while 97% in liquid phase at 1100 ℃. Finally, the predicted data were compared with the experimental results showing good agreement with each other.

Modeling constitutive relationship of 6013 aluminum alloy during hot plane strain compression based on Kriging method

Hot plane strain compression tests of 6013 aluminum alloy were conducted within the temperature range of 613?773 K and the strain rate range of 0.001?10 s?1. Based on the corrected experimental data with temperature compensation, Kriging method is selected to model the constitutive relationship among flow stress, temperature, strain rate and strain. The predictability and reliability of the constructed Kriging model are evaluated by statistical measures, comparative analysis and leave-one-out cross-validation (LOO-CV). The accuracy of Kriging model is validated by the R-value of 0.999 and the AARE of 0.478%. Meanwhile, its superiority has been demonstrated while comparing with the improved Arrhenius-type model. Furthermore, the generalization capability of Kriging model is identified by LOO-CV with 25 times of testing. It is indicated that Kriging method is competent to develop accurate model for describing the hot deformation behavior and predicting the flow stress even beyond the experimental conditions in hot compression tests.

Comparative analysis of isothermal and non-isothermal solidification of binary alloys using phase-field model

Based on the entropy function, a two-dimensional phase field model of binary alloys was established. Meanwhile, an explicit difference method with uniform grid was adopted to solve the phase field and solute field controlled equations. And the alternating direction implicit(ADI) algorithm for solving temperature field controlled equation was also employed to avoid the restriction of time step. Some characteristics of the Ni-Cu alloy were captured in the process of non-isothermal solidification, and the comparative analysis of the isothermal and the non-isothermal solidification was investigated. The simulation results indicate that the non-isothermal model is favorable to simulate the real solidification process of binary alloys, and when the thermal diffusivity decreases, the non-isothermal phase-field model is gradually consistent with the isothermal phase-field model.

High-temperature flow behavior modeling of 2099 alloy considering strain effects

Isothermal compression tests in a wide range of temperatures （300-500 ℃） and strain rates （0.001-10 s^-1）, were performed on 2099 alloy to reveal the hot deformation characteristics. In order to give a precise prediction of flow behavior, the obtained experimental data were modified by friction and temperature correction and then employed to derive the constitutive modeling. The effects of the temperature and strain rate on hot deformation behavior can be expressed by Zener-Hollomon parameter including Arrhenius term. Furthermore, the influence of strain was incorporated in the constitutive analysis by considering the effect of strain on material constants （i.e. a, n, Q and A）. Consequently, the flow stress curves predicted by the developed modeling show a good agreement with the corrected ones, which indicates that the developed constitutive modeling could give an accurate and precise prediction for the flow stress of 2099 alloy.

Experiments and modeling of double-peak precipitation hardening and strengthening mechanisms in Al-Zn-Mg alloy

The aim of the present work is to develop a model for simulating double-peak precipitation hardening kinetics in Al-Zn-Mg alloy with the simultaneous formation of different types of precipitates at elevated temperatures based on the modified Langer-Schwartz approach. The double aging peaks are present in the long time age-hardening curves of Al-Zn-Mg alloys. The physically-based model, while taking explicitly into account nucleation, growth, coarsening of the new phase precipitations and two strengthening mechanisms associated with particle-dislocation interaction （shearing and bypassing）, was used for the analysis of precipitates evolution and precipitation hardening during aging of Al-Zn-Mg alloy. Model predictions were compared with the measurements of Al-Zn-Mg alloy. The systematic and quantitative results show that the predicted hardness profiles of double peaks via adding a shape dependent parameter in the growth equation for growth and coarsening generally agree well with the measured ones. Two strengthening mechanisms associated with particle-dislocation interaction （shearing and bypassing） were considered operating simultaneously in view of the particle size-distribution. The transition from shearing to bypassing strengthening mechanism was found to occur at rather early stage of the particle growth. The bypassing was found to be the prevailing strengthening mechanism in the investigated alloys.

Tribological properties and wear prediction model of TiC particles reinforced Ni-base alloy composite coatings

TiC particles reinforced Ni-based alloy composite coatings were prepared on 7005 aluminum alloy by plasma spray. The effects of load, speed and temperature on the tribological behavior and mechanisms of the composite coatings under dry friction were researched. The wear prediction model of the composite coatings was established based on the least square support vector machine (LS-SVM). The results show that the composite coatings exhibit smaller friction coefficients and wear losses than the Ni-based alloy coatings under different friction conditions. The predicting time of the LS-SVM model is only 12.93%of that of the BP-ANN model, and the predicting accuracies on friction coefficients and wear losses of the former are increased by 58.74%and 41.87%compared with the latter. The LS-SVM model can effectively predict the tribological behavior of the TiCP/Ni-base alloy composite coatings under dry friction.

Thermal modeling of underwater friction stir welding of high strength aluminum alloy

The thermal modeling of underwater friction stir welding （FSW） was conddcted with a three-dimensional heat transfer model. The vaporizing characteristics of water were analyzed to illuminate the boundary conditions of underwater FSW. Temperature dependent properties of the material were considered for the modeling. FSW experiments were carried out to validate the calculated results, and the calculated results showed good agreement with the experimental results. The results indicate that the maximum peak temperature of underwater joint is significantly lower than that of normal joint, although the surface heat flux of shoulder during the underwater FSW is higher than that during normal FSW. For underwater joint, the high-temperature distributing area is dramatically narrowed and the welding thermal cycles in different zones are effectively controlled in contrast to the normal joint.

Deformation mechanisms of Mg-3Al-1Zn alloy by polycrystal plasticity modeling

A polycrystal plasticity model was developed to analyze the room-temperature deformation behaviors of Mg-3A1-1Zn alloy（AZ31）.The uniaxial tension and compression tests at room temperature were conducted using cast and extruded AZ31 rods with different textures and combined with the proposed model to reveal the deformation mechanisms.It is shown that,different flow curves of two specimens under tension and compression tests can be simulated by this model.The flow curves of AZ31 extrusions exhibit different shapes for tension and compression due to different activities of tensile twinning and pyramidalc＋a slip.The metallographic and TEM observations showed the equal twinning activities at the initial stage in tension and compression tests and the occurrence of pyramidalc＋a slip in compression of as-cast Mg-3A1-1Zn alloy with increasing the strain,which is consistent with the simulated results by the proposed model.

Multi-field dynamic modeling and numerical simulation of aluminum alloy resistance spot welding

In order to explore the influence of welding parameters and to investigate the Al alloy (AA) nugget formation process, a comprehensive model involving electrical-thermal-mechanical and metallurgical analysis was established to numerically display the resistance spot welding (RSW) process within multiple fields and understand the AA-RSW physics. A multi-disciplinary finite element method (FEM) framework and a empirical sub-model were built to analyze the affecting factors on weld nugget and the underlying nature of welding physics with dynamic simulation procedure. Specifically, a counter-intuitive phenomenon of the resistance time-variation caused by the transient inverse virtual variation (TIVV) effect was highlighted and analyzed on the basis of welding current and temperature distribution simulation. The empirical model describing the TIVV phenomenon was used for modifying the dynamic resistance simulation during the AA spot welding process. The numerical and experimental results show that the proposed multi-field FEM model agrees with the measured AA welding feature, and the modified dynamic resistance model captures the physics of nugget growth and the electrical-thermal behavior under varying welding current and fluctuating heat input.

Simulation of pre-precipitation in Ni_(75)Al_(14)Mo_(11) alloy by microscopic phase-field model

The early precipitation process of Ni（75）Al（14）Mo（11） alloy was simulated by microscopic phase-field model at different temperatures.The microstructure of the alloy,the precipitation time of Llo structure and occupation probability of the three kinds of atoms were investigated.It is indicated that the non-stoichiometric Ll0（Ⅰ/Ⅱ） phases are found in the precipitation process.With the temperature increasing,the appearance time of Ll0 is brought forward.The Ll0（Ⅱ） structure always precipitates earlier than the Ll0（Ⅰ） structure.Compared with lower temperature,higher temperature brings the formation time of Ll0 phase forward and makes Ll0 phase have a higher order degree.But lower temperature shortens the process time of the Ll0 phase to the Ll2 phase.Al and Mo atoms tend to occupy γ site,Ni atom tends to occupy a and β sites.At the same temperature,Al atom has stronger occupation ability than Mo atom in the same site.Ni,Al and Mo collectively form the composited Ll2 structure.