航空用GH625镍基高温合金带材的成形极限研究

目的 通过理论预测及胀形实验建立GH625高温合金的成形极限曲线,并结合仿真手段揭示其成形性能.方法 首先,通过基本力学性能测试获取不同方向下GH625材料的基本力学参数;然后,基于颈缩理论和M-K理论模型预测GH625材料的成形极限曲线;其次,通过胀形实验建立相应的成形极限图,并与理论结果进行对比;最后,结合有限元方法进一步研究GH625材料的成形特性.结果 准确获得了GH625高温合金的塑性应变比r值、应变硬化指数n值等参数;通过理论模型及胀形实验分别获得了相应的成形极限曲线,基于颈缩理论的集中性失稳预测结果与实验结果吻合较好;建立了可靠的有限元模型,进一步分析了摩擦因数及球头直径对GH625材料成形性能的影响规律.结论 建立了准确的GH625材料成形极限曲线的理论预测模型,并通过半球胀形实验验证了理论结果的可靠性,数值仿真结果发现,较小的摩擦因数或者冲头直径有利于改善GH625材料在胀形实验中的失效位置.     

Experimental evaluation and prediction of forming limit of FSW blanks made of AA 6061 T6 sheets at different weld orientations and weld locations

The main objective of the present work is to predict the forming limit of friction stir welded (FSW) sheets made of AA 6061T6, having different weld orientations, weld locations, and made at two different welding speeds. The predicted forming limit curves (FLCs) are validated with experimental FLCs. The thickness gradient based necking criterion (TGNC) and major strain‐rate ratio based necking criterion (MSRC) are used to predict the forming limit. The significance of single zone model and double zone model in FLC prediction is discussed. A decrease in hardness is witnessed in the weld zone as compared to base material. With increase in shoulder diameter and decrease in rotational speed, hardness has improved in the weld zone. The forming limit predictions of un‐welded sheets and FSW sheets coincide well with experimental results. The predicted FLCs of FSW sheets from TGNC and MSRC are equally accurate as compared to experimental FLCs in all the weld locations. Both TGNC and MSRC predict almost the same forming limit in 90° weld orientation, while TGNC showed better prediction in 45° weld orientation. FSW sheets with double zone models show better prediction accuracy than single zone models in most of the cases, except in the case of weld at centre location and at longitudinal orientation. There is only slight deviation between single zone and double zone model predictions. The failure location and failure pattern predictions are also agreeing well with the experimental FLCs.     

A numerical analysis of sheet metal formability for automotive stamping applications

A theoretical failure model is presented for the numerical prediction of the forming limit strains of automotive sheets. The model uses the Swift’s diffuse necking and Hill’s localized necking concepts in describing tearing-type sheet metal failures and a computational scheme is proposed in which the failure conditions are expressed in incremental forms. The Bauschinger effect is included properly in the deformation modeling using an additive backstress form of the nonlinear-kinematic hardening rule. The necking conditions and plasticity model are transformed into a set of algebraic equations that may be applied both for proportional and non-proportional strain-controlled loadings. An iterative approach is employed in the incremental solution of algebraic equations. The formability analyses are conducted using the proposed theoretical model and the forming limit strains of two new generation auto sheets (Trip600 1.4 mm, DP980 1.15 mm) are estimated. The numerically generated FLC are compared with the experimental data and the FLC calculated with the Keeler–Brazier equation. For both steels, the model produced conservative plain–strain intercept values, FLC₀, when compared with the predictions of Keeler–Brazier equation. Also the negative minor strain part of the experimental FLD’s is estimated with sufficient accuracy. For the positive minor strain side, however, the predictions are lower than both the experimental fit and the standard curve.     

Studies on the stress-strain relations of dual-phase steels

The correlations of the work-hardening exponent,n, with quenching temperature, martensite volume-fraction (MVF) and solute concentration in ferrite are discussed and derived for dual-phase steel. The flow stress of dual-phase steel at low strain is suggested to be expressed by the combination of the terms due to plastic deformation in ferrite and elastic deformation of martensite. Previous experimental results are compared with the behaviour suggested by this theoretical work. In addition, an expression for the work hardening exponents at moderate strains and at the onset of necking are also theoretically suggested.     

Cyclic deformation behavior of austenitic Cr–Ni-steels in the VHCF regime: Part II – Microstructure-sensitive simulation

In Part I – Experimental study, the cyclic deformation behavior of two austenitic stainless steel grades (AISI 304, AISI 316 L) were experimentally investigated at low stress amplitudes in the very high cycle fatigue (VHCF) regime. The observations indicate that during VHCF the metastable austenitic stainless steel (304 grade) performs a pronounced localization of plastic deformation in shear bands followed by a deformation-induced martensitic phase transformation. The 316 grade undergoes only a very limited local plastic deformation in shear bands with almost no phase transformation. Consequently, both materials exhibit distinctly different cyclic softening and hardening characteristics during VHCF. In order to provide a more detailed knowledge about the individual deformation mechanisms and their effect on the cyclic softening and hardening behavior the experimental study is extended by microstructure-sensitive modeling and simulation. Two-dimensional (2-D) microstructures consisting of several grains are represented using the boundary element method and plastic deformation within the microstructure is considered by a mechanism-based approach. Specific mechanisms of cyclic plastic deformation in shear bands and deformation-induced martensitic phase transformation – as documented by experimental results and based on well-known model approaches – are defined and implemented into the simulation. The fatigue behavior at low stress amplitudes observed in experiments can be well represented in simulations so that the underlying model helps to understand the cyclic deformation behavior of austenitic stainless steels at low stress amplitudes in the regime of VHCF strength. In a comparative study based on the resonant behavior the effect of certain deformation mechanisms on the global cyclic softening and hardening characteristics is pointed out for both materials.     

Investigation on the strain-path dependency of stress-based forming limit curves

Path-dependent forming limits have been computed for sheet metals undergoing various combinations of plane stress loading conditions. This paper presents a theoretical model for prediction of stress-based forming limit curves (SFLC) based on the Marciniak and Kuczynski (MK) model. Acceptable agreement was observed between calculated forming limit curves (FLC) and experimental data for AISI-1012 steel (Molaei 1999) and AA-2008-T4 alloys (Graf and Hosford Metallurgical Trans 24A:2503–2512, 1993). In this paper, the path dependency of SFLCs predicted for different non-proportional loading histories has been investigated. For a range of prestrain values in different bilinear loading paths, the SFLC remains practically unchanged. However, some strain path dependency is observed for large values of prestrain ( $ \bar{\varepsilon } \geqslant 0.35 $ for AISI-1012 steel) and for abrupt changes in strain path. Nevertheless, the SFLC remains a good failure criterion for virtual forming simulations because the path dependency of SFLCs is much less significant than that of strain-based FLCs.     

Stress based prediction of formability and failure in incremental sheet forming

A strain-based forming limit criterion is widely used in sheet-metal forming industry to predict necking. However, this criterion is usually valid when the strain path is linear throughout the deformation process [1]. Strain path in incremental sheet forming is often found to be severely nonlinear throughout the deformation history. Therefore, the practice of using a strain-based forming limit criterion often leads to erroneous assessments of formability and failure prediction. On the other hands, stress-based forming limit is insensitive against any changes in the strain path and hence it is first used to model the necking limit in incremental sheet forming. The stress-based forming limit is also combined with the fracture limit based on maximum shear stress criterion to show necking and fracture together. A derivation for a general mapping method from strain-based FLC to stress-based FLC using a non-quadratic yield function has been made. Simulation model is evaluated for a single point incremental forming using AA 6022-T43, and checked the accuracy against experiments. By using the path-independent necking and fracture limits, it is able to explain the deformation mechanism successfully in incremental sheet forming. The proposed model has given a good scientific basis for the development of ISF under nonlinear strain path and its usability over conventional sheet forming process as well.     

Analysis of the extended stress-based forming limit curve considering the effects of strain path and through-thickness normal stress

In this study, an approach based on the modified Marciniak–Kuczynski (M–K) method for computation of an extended stress-based forming limit curve (FLC) is presented. The extended stress-based FLC is built based on equivalent plastic stress versus mean stress. This curve has some advantages in comparison with the conventional FLC. This new criterion is much more strain path independent than the conventional FLC. The effect of strain path on the predicted extended stress-based FLC is reexamined. For this purpose, two types of pre-straining on the sheet metal have been loaded. Moreover, the plane stress state assumption is not adopted in the current study. The influence of a through-thickness compressive normal stress is also investigated theoretically. The verifications of the theoretical FLCs are performed by using some available published experimental data.     

304不锈钢箔材在不同应变速率下的拉伸性能研究

304不锈钢是一种常用的奥氏体不锈钢.在拉伸应变过程中,应变速率的变化会诱发马氏体转变量和转变速率,以及内部组织滑移线、位错、层错、形变孪晶密度的转变量和转变速率的不同,从而表现出不同的应变硬化行为.本文针对0.1 mm厚度304奥氏体不锈钢箔材,从断后伸长率,断面收缩率,屈服强度,抗拉强度及硬化指数5个方面,研究了室温条件下不同应变速率对其拉伸性能的影响.实验结果表明：马氏体转变理论同样适用于304奥氏体不锈钢箔材, 且0.1 mm厚度304不锈钢存在“越薄越脆,越小越强”的尺寸效应现象;同时,0.1 mm厚度304奥氏体不锈钢箔材拉伸力学性能随应变速率的变化主要表现在以下几方面：断后延伸率和断面收缩率均随着应变速率的增加而降低;低应变速率时,随着应变速率的增加屈服强度增大,而抗拉强度随应变速率的提高呈现减弱的相反规律;高应变速率下,304奥氏体不锈钢的强度主要由材料本身性能决定,应变速率的改变对强度的影响较小;准静态低应变速率下,硬化指数随应变速率增大而升高,较高应变速率下,硬化指数与应变速率变化无关.     

Influence of out-of-plane compression stress on limit strains in sheet metals

The prediction of the forming limits of sheet metals typically assumes plane stress conditions that are really only valid for open die stamping or processes with negligible out-of-plane stresses. In fact, many industrial sheet metal forming processes lead to significant compressive stresses at the sheet surface, and therefore the effects of the through-thickness stress on the formability of sheet metals cannot be ignored. Moreover, predictions of forming limit curves (FLC) that assume plane stress conditions may not be valid when the forming process involves non-negligible out-of-plane stresses. For this reason a new model was developed to predict FLC for general, three-dimensional stress states. Marciniak and Kuczynski (Int J Mech Sci 9:609-620, 1967) first proposed an analytical method to predict the FLC in 1967, known as the MK method, and this approach has been used for decades to accurately predict FLC for plane stress sheet forming applications. In this work, the conventional MK analysis was extended to include the through-thickness principal stress component (σ ₃), and its effect on the formability of different grades of sheet metal was investigated in terms of the ratio of the third to the first principal stress components (). The FLC was predicted for plane stress conditions (β = 0) as well as cases with different compressive through-thickness stress values (β ≠ 0) in order to study the influence of β on the FLC in three-dimensional stress conditions. An analysis was also carried out to determine how the sensitivity of the FLC prediction to the through-thickness stress component changes with variations in the strain hardening coefficient, in the strain rate sensitivity, in plastic anisotropy, in grain size and in sheet thickness. It was found that the out-of-plane stress always has an effect on the position of the FLC in principal strain space. However, the analysis also showed that among the factors considered in this paper, the strain hardening coefficient has the most significant effect on the dependency of FLC to the through-thickness stress, while the strain rate sensitivity coefficient has the least influence on this sensitivity.     

Large elastic strains and ductile necking of W nanowires embedded in TiNi matrix

The deformation behaviors of W nanowires embedded in a TiNi matrix were investigated by means of in-situ synchrotron high energy X-ray diffraction(HEXRD) and in-situ transmission electron microscopy(TEM) analysis during tensile deformation.The HEXRD measurement indicated that the W nanowires exhibited an average lattice strain of about 1.50 %,whereas the TEM examination revealed a local elastic strain of about 4.59 % in areas adjacent to the TiNi matrix where stress-induced martensitic transfo rmation occurred.This strain corresponds to a stress of ~15 GPa for the W nanowires.In addition,in areas adjacent to the TiNi matrix where plastic deformation and cracking were generated,the W nanowire showed significant ductile necking with ~80 % reduction in cross-section area.The ductile necking of W nanowire is attributed to the lack of protection from the stress-induced martensitic transformation of the TiNi matrix.     

Dynamic Recrystallization Behavior of 13%Cr Martensitic Stainless Steel under Hot Working Condition

In this study,the effect of hot deformation on martensitic stainless steel was carried out in temperatures between 950 to 1100℃and strain rates of 0.001,0.01 and 0.1 s-1.Two important dynamic recrystallization parameters,the critical strain and the point of maximum dynamic softening,were derived from strain hardening rate vs stress curves.Then the calculated parameters were used to predict the dynamic recrystallized fraction.Our results show that critical stress and strain increase with decreasing deformation temperature and increasing strain rate.The hot deformation activation energy of the steel is also investigated in the present work with 413 kJ/mol.Our experimental flow curves are in fair agreement with the kinetics of dynamic recrystallization model.     

Crystallographic texture evolution and martensite transformation in the strain hardening process of a ferrite-based low density steel

The strain-induced martensite transformation is of great importance in the strain hardening process of ferrite based low-density steel.Based on the microstructure analysis,the texture evolution and martensite transformation behavior in the strain hardening process were studied.The results show that martensite transformation accompanied by TWIP effect and high density dislocations maintains the con-tinuous hardening stage.As the strain increases,the texture of retained austenite evolves towards the F orientation{111}〈112〉,which is not conducive to martensite transformation.After the strain of 5％,the number of austenite grains with high Schmid factor orientations is gradually increased,and then signif-icantly reduced when the strain is over 10％due to the occurrence of martensitic transformation,which results in a high martensitic transformation rate.However,the unfavorable orientation and the reduced grain size of austenite slow down the martensite transformation at the final hardening stage.Moreover,because of the coordination deformation of austenite grains,strain preferentially spreads between adja-cent austenite grains.Consequently,the martensite transformation rate in strain hardening process is dependent on the orientation and grain size evolution of austenite,leading to a differential contribution to each strain hardening stage.     

Determination of critical strain for initiation of dynamic recrystallization

Using the work hardening rate–strain curves, an effective mathematical model has been developed to predict the stress–strain curves of alloy steel during hot deformation up to the peak stress regardless of the level of the strain, weather smaller or larger than the critical strain. This model is expressed in terms of peak stress, peak strain and one temperature-sensitive parameter, S. In addition, one new model, which is a function of peak strain, was proposed to predict the critical strain for the initiation of dynamic recrystallization using the second derivative of work hardening rate with respect to stress. Besides the theoretical study, the analysis is used to determine the stress–strain curves and critical strain of 304 austenitic stainless steel. The predicted results were found to be in accord with the experimental data.     

Analysis of the Transformation-induced Plasticity Effect during the Dynamic Deformation of High-manganese Steel

The transformation-induced plasticity(TRIP) effect and resistance characteristics to adiabatic shear failure at high strain rates of high-manganese steel were investigated by using scanning electron microscopy and electron backscattering diffraction. Results showed that the high-manganese steel exhibited excellent strain hardening effect and resistance to adiabatic shear failure because of the TRIP effect. The TRIP effect occurred during dynamic deformation and showed two distinct stages,namely,the smooth TRIP process before the formation of adiabatic shear band(ASB) and the inhibited TRIP process during further deformation. In the first stage,the martensitic transformation showed slight orientation dependence and weak variant selection,which promoted the TRIP effect. In the second stage,reverse martensitic transformation occurred. Adiabatic shear bands(ASBs) developed typical shear microtextures {111}<110>. In microtextures,two groups of fine grains are in a twin relationship and uniform distribution,which restrained the formation of holes and cracks within the ASBs and enhanced damage resistance after ASB formation.     

Inter-relation between true stress at the onset of necking and true uniform strain in steels – A manifestation of onset to plastic instability

A linear relation is observed between the true stress at the onset of necking and true uniform strain in type 316L(N) austenitic steel and P91 ferritic steel over wide range of test conditions. The observed linear relation between the true stress at the onset of necking and true uniform strain has been rationalised in terms of the onset to plastic instability. The strain regime, over which the alloy deforms by stable plastic flow, is directly proportional to the tensile strength.     

Further observations on the plastic deformation of a normalized low carbon steel

The plastic deformation of a commercial grade low carbon steel has been investigated using microhardness and grain strain measurement techniques. Two distinct modes of deformation during plastic flow in low carbon ferritic steel have been identified. The initial stage involves the propagation of the Luder's band along the gauge length of the sample by slip strain in the surface and near surface grains only, the strain accommodation in the interior of the material being attained by a predominantly grain translation mode. The second stage involves the propagation of a strain hardening front through the cross-section of the material as the macro-strain is increased through the flow stress region.     

Analyses of route Bc equal channel angular pressing and post-equal channel angular pressing behavior by the finite element method

Equal channel angular pressing (ECAP) process provides an efficient procedure for achieving ultrafine grained microstructures with excellent mechanical properties in metallic materials. In this article, a simulation scheme for predicting the mechanical behavior during and after ECAP was proposed. The proposed scheme was applied for interstitial-free (IF) steels, which are widely used for the automobile body applications. Plastic deformation behavior during several passes of ECAP in route Bc, including such aspect as deformed geometry, corner gap, forming load and strain uniformity, was predicted. Tensile testing responses of the ECAP-processed IF steel, including strain hardening, onset of necking, and post-necking behavior, were analyzed using the finite element method and compared with the experimental results. The predicted tensile curves, ultimate tensile strength, and elongation varying with the number of ECAP passes were in good agreement with experimental results. The computational scheme developed was demonstrated to successfully predict not only the plastic deformation behavior during ECAP but also the mechanical properties of the ECAP-processed material.     

Low-cycle fatigue behavior and microstructural evolution in a low-carbon carbide-free bainitic steel

This paper deals with the cyclic deformation behavior and microstructural evolution in a low-carbon carbide-free bainitic steel with two different microstructures. Low-cycle fatigue tests were performed at room temperature at various strain amplitudes under total strain control. The variations of the amount of retained austenite and the substructures versus the number of fatigue cycles were evaluated by the X-ray diffraction technique and electron microscopy. Fatigue test results demonstrate that the two microstructures exhibit very similar cyclic stress responses, i.e. initial cyclic hardening followed by cyclic softening or by cyclic saturation and softening till failure, depending on the strain amplitude applied. Parametric studies of the microstructure–property relationship indicate that the major cause for the initial cyclic hardening is neither martensitic transformation nor increased dislocation density. Based on these results and considering the initial high density of dislocations, which are pre-existent and mobile in the starting microstructure and which are entangled, rearranged or annihilated with cycling, the mechanisms responsible for the initial cyclic hardening followed by softening are analyzed.     

Cyclic strain rate effect on martensitic transformation and fatigue behaviour of an austenitic stainless steel

In this study, the effect of strain rate on the cyclic behaviour of 304L stainless steel is investigated to unveil the complex interrelationship between martensitic phase transformation, secondary hardening, cyclic deformation and fatigue behaviour of this alloy. A series of uniaxial strain controlled fatigue tests with varying cyclic strain rates were conducted at zero and non‐zero mean strain conditions. Secondary hardening was found to be closely related to the volume fraction of strain‐induced martensite which was affected by adiabatic heating due to increasing cyclic strain rates. Tests with lower secondary hardening rates maintained lower stress amplitudes during cyclic loading which resulted in longer fatigue lives for similar strain amplitudes. Fatigue resistance of 304L stainless steel was found to be more sensitive to changes in strain rate than the presence of mean strain. The mean strain effect was minimal due to the significant mean stress relaxation in this material.