Title: Digital Image Correlation Analysis of Uniform Deformation and Necking in Solid‐State Welded Nanocrystalline Aluminum via High‐Pressure Torsion
Solid‐state welding of Al 1043 sheets is achieved via high‐pressure torsion (HPT) processing to produce bulk nanostructured Al disks. A homogeneous nanostructure without segregation is observed, with grain sizes of ≈430–470 nm. Miniature tensile testing, coupled with the digital image correlation (DIC) technique, is employed to determine the room‐temperature tensile deformation behavior, particularly the nonuniform behavior with necking, of the HPT‐bonded ultrafine‐grained (UFG) aluminum, comparing it with annealed coarse‐grained counterpart. The HPT‐bonded UFG Al exhibits a large fraction of post‐necking strain, which is supported by the estimated high strain rate sensitivity value ofm = 0.085, suggesting the delay of local necking leading to tensile fracture. Detailed DIC analysis reveals prolonged diffuse necking, thus delaying local necking, in the HPT‐bonded UFG Al, while the annealed samples show high fractions of local necking during the nonuniform deformation. Moreover, the DIC data illustrate that local necking predominantly occurred at a limited neck zone, maintaining a plateau strain distribution at the out‐of‐neck zone throughout necking deformation toward tensile failure for both annealed and UFG aluminum. The DIC method offers an alternative means to demonstrate the transition in necking behaviors of materials by estimating the plastic lateral contraction exponent. more »« less
Kawasaki, Megumi; Langdon, Terence G.
(, Materials Science Forum)
null
(Ed.)
Processing through the application of high-pressure torsion (HPT) provides significant grain refinement in bulk metals at room temperature. These ultrafine-grained (UFG) materials after HPT generally demonstrate exceptional mechanical properties. Recent reports demonstrated the bulk-state reactions for mechanical bonding of dissimilar lightweight metal disks to synthesize hybrid alloy systems by utilizing conventional HPT processing. Accordingly, the present report provides a comprehensive summary of the recent work on processing of several UFG hybrid alloy systems including Al-Mg and Al-Cu by HPT under 6.0 GPa at room temperature and a special emphasis was placed on understanding the evolution of hardness. This study demonstrates a significant opportunity for the application of HPT for a possible contribution to current enhancements in diffusion bonding, welding and mechanical joining technologies as well as to an introduction of hybrid engineering nanomaterials.
Severe plastic deformation (SPD) has been known for decades to provide microstructural refinement under a hydrostatic stress state by introducing a tremendous quantity of lattice defects, including vacancies, dislocations, and grain boundaries, leading to enhanced mechanical properties. Many SPD processes have been well studied and utilized for the processing of ultrafine-grained (UFG) metals and materials. One major challenge with SPD-processed UFG materials is their limited applicability, primarily due to their microstructural stability at elevated temperatures and the difficulty of scaling up to larger sizes or volumes. To first understand the thermal stability of UFG material, a copper prepared by high-pressure torsion, a technique that can achieve true nano-scale grains in bulk samples, was evaluated using two novel in situ techniques of micro-beam high-energy synchrotron X-ray diffraction. These are, namely, monochromatic X-ray beams that yield changes in microstructure with time and temperature, and a polychromatic X-ray beam that determines grain reorientation behavior during microstructural relaxation. Furthermore, a new processing technique named cold angular rolling process (CARP) demonstrated some promise as an SPD technique for producing theoretically unlimited lengths of strength-enhanced copper sheets at room temperature with a relatively low energy consumption. Additional miniature tensile testing incorporating digital image correlation (DIC) method and microstructural analysis utilizing high-energy X-ray diffraction determined the influence of CARP having higher shear strain hardening in comparison with other established techniques. This study highlights the significance of lattice-defect influenced mechanical properties and microstructure of UFG obtained across multi-length scales and volumes, which are critical for guiding the control and scalable production of advanced materials for commercialization.
Guo, Bicheng; Gao, Zhongfang; Gerini-Romagnoli, Marco; Yang, Lianxiang
(, American Society of Mechanical Engineers)
Abstract Carbon and glass fiber-reinforced plastic (CFRP and GFRP) composites have gained popularity in various industries and settings owing to their exceptional strength-to-weight ratio, corrosion resistance, fatigue resistance, and design flexibility. Adhesives are commonly utilized to bond carbon fiber reinforced plastics to other materials or to themselves. Bonded joints have been found to enhance the mechanical characteristics of materials, while also reducing additional costs for practical applications. The bonding region’s strength can be influenced by different material combinations and substrate thicknesses. The present investigation employed a double-sided multi-digital image correlation (DS-Multi-DIC) system to quantify the deformation and fracture mechanisms of adherends during tensile testing. The primary objective was to assess the static impact on the strength of the bonded zone under tensile loading. The system comprises of two stereo vision DIC measurement systems, wherein each system comprises of two GigE cameras. These cameras are positioned at the front and back of the sample, respectively the process of system calibration involves the utilization of the double-sided calibration technique to integrate the coordinate systems of the two DIC measurement subsystems with the global coordinate system. This enables the direct measurement of deformation and strain in three dimensions. This paper examines the impact of adhesive thickness and type on the strength of the bonded area and fracture mechanism by analyzing the alteration in strain distribution and maximum strain during static stretching. The study yielded a conclusion that the magnitude of the bonded region’s strength is positively correlated with the thickness of the bonding material. The cohesive force of the bonded region is positively correlated with the malleability of the adhesive bond. Furthermore, an examination was conducted on the impact of adhesive thickness and type on peeling strain. As the bond’s bending stiffness diminishes, there is a corresponding increase in the peel strain it undergoes. Furthermore, a succinct description is provided regarding the unequal allocation of auditory alterations that occur during stationary stretching.
The mechanical bonding of dissimilar metals though the application of high‐pressure torsion (HPT) processing is developed recently for introducing unique ultrafine‐grained alloy systems involving microstructural heterogeneity leading to excellent mechanical properties. Considering further developments of the processing approach and the produced hybrid materials, the size effect on microstructural evolution and micromechanical responses of the mechanically bonded Al–Mg systems is evaluated. In practice, processing by HPT is conducted at room temperature on the separate Al and Mg disks having 25 mm diameter under 1.0 GPa at 0.4 rpm, and the results are compared with the mechanically bonded Al–Mg system having 10 mm diameter. The Al–Mg disks having 25 mm diameter show a general hardness distribution where low hardness appears around the disk centers, and it increases at the disk peripheries. Nanoindentation measurements demonstrate that there is excellent plasticity at the edges of the Al–Mg system with 25 mm diameter. The Al–Mg system with both 10 and 25 mm diameters show a consistent trend of hardness evolution outlining an exponential increase of hardness with increasing equivalent strain. The results are anticipated to provide a conceptual framework for the development and scale‐up of the HPT‐induced mechanical bonding technique.
Siefert, W.; Buehner, M.; Alexandrov, B. T.
(, Welding in the World)
The local yielding behavior in base metal, heat-affected zone, fusion boundary region, and weld metal of low-alloy steel/Alloy 625 filler metal welds was quantified using digital image correlation instrumented cross-weld tensile test. The tested welds exhibited undermatching, matching, or overmatching weld metal yield strength with significant gradients in the local yielding behavior. An undermatching weld yielded at 69 MPa below the base metal yield stress, accumulating to 0.72% total strain. The base metal in an overmatching weld had 110 MPa lower yield strength than the weld metal. The strong strain hardening response in the Alloy 625 weld metal, within the uniform elongation range, and its constraining effect on the fusion boundary region and heat affected zone, led to extensive strain accumulation, necking, and final failure in the base metal of all tested welds. The yielding behavior of the tested welds was compared to stress-based criteria, utilizing minimum specified and as-delivered yield and ultimate tensile strength, and to strain-based criteria. The capability of digital image correlation instrumented cross-weld tensile testing to quantify local yielding and strain accumulation demonstrates potential application in proving conformity to stress-based and strain-based design criteria of dissimilar and matching filler metal welds.
Bhatta, Laxman, Lee, Isshu, Figueiredo, Roberto_B, Bay, Brian_K, and Kawasaki, Megumi. Digital Image Correlation Analysis of Uniform Deformation and Necking in Solid‐State Welded Nanocrystalline Aluminum via High‐Pressure Torsion. Advanced Engineering Materials 26.19 Web. doi:10.1002/adem.202400439.
@article{osti_10507046,
place = {Country unknown/Code not available},
title = {Digital Image Correlation Analysis of Uniform Deformation and Necking in Solid‐State Welded Nanocrystalline Aluminum via High‐Pressure Torsion},
url = {https://par.nsf.gov/biblio/10507046},
DOI = {10.1002/adem.202400439},
abstractNote = {Solid‐state welding of Al 1043 sheets is achieved via high‐pressure torsion (HPT) processing to produce bulk nanostructured Al disks. A homogeneous nanostructure without segregation is observed, with grain sizes of ≈430–470 nm. Miniature tensile testing, coupled with the digital image correlation (DIC) technique, is employed to determine the room‐temperature tensile deformation behavior, particularly the nonuniform behavior with necking, of the HPT‐bonded ultrafine‐grained (UFG) aluminum, comparing it with annealed coarse‐grained counterpart. The HPT‐bonded UFG Al exhibits a large fraction of post‐necking strain, which is supported by the estimated high strain rate sensitivity value ofm = 0.085, suggesting the delay of local necking leading to tensile fracture. Detailed DIC analysis reveals prolonged diffuse necking, thus delaying local necking, in the HPT‐bonded UFG Al, while the annealed samples show high fractions of local necking during the nonuniform deformation. Moreover, the DIC data illustrate that local necking predominantly occurred at a limited neck zone, maintaining a plateau strain distribution at the out‐of‐neck zone throughout necking deformation toward tensile failure for both annealed and UFG aluminum. The DIC method offers an alternative means to demonstrate the transition in necking behaviors of materials by estimating the plastic lateral contraction exponent.},
journal = {Advanced Engineering Materials},
volume = {26},
number = {19},
publisher = {Wiley Blackwell (John Wiley & Sons)},
author = {Bhatta, Laxman and Lee, Isshu and Figueiredo, Roberto_B and Bay, Brian_K and Kawasaki, Megumi},
}
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