Characterisation and investigation of local variations in mechanical behaviour in cast aluminium using gradient solidification,Digital Image Correlation and finite element simulation

Due to design and process-related factors, there are local variations in the microstructure and mechanical behaviour of cast components. This work establishes a Digital Image Correlation (DIC) based method for characterisation and investigation of the effects of such local variations on the behaviour of a high pressure, die cast (HPDC) aluminium alloy. Plastic behaviour is studied using gradient solidified samples and characterisation models for the parameters of the Hollomon equation are developed, based on microstructural refinement. Samples with controlled microstructural variations are produced and the observed DIC strain field is compared with Finite Element Method (FEM) simulation results. The results show that the DIC based method can be applied to characterise local mechanical behaviour with high accuracy. The microstructural variations are observed to cause a redistribution of strain during tensile loading. This redistribution of strain can be predicted in the FEM simulation by incorporating local mechanical behaviour using the developed characterisation model. A homogeneous FEM simulation is unable to predict the observed behaviour. The results motivate the application of a previously proposed simulation strategy, which is able to predict and incorporate local variations in mechanical behaviour into FEM simulations already in the design process for cast components.     

球墨铸铁表面电弧增材制造Fe‒Cr合金结合区组织和性能

目的 在球墨铸铁基体上电弧增材制造Fe-Cr合金,研究结合区组织和性能,以期获得具有良好冶金结合、满足冲裁模具性能要求的双金属构件。方法 采用GMAW工艺增材制造,用金相显微镜和扫描电子显微镜表征结合区的显微组织,并分析其形成机制。结果 Fe-Cr合金与球墨铸铁结合区无明显裂纹和气孔,其凝固组织为柱状晶和等轴晶,冷却后转变为马氏体和残余奥氏体,但其分布不均匀,在界面处有一富奥氏体层。结合区内球墨铸铁受热影响发生奥氏体化和部分熔化,熔化发生在临近结合界面的石墨球周围,其冷却后形成一层马氏体和一层莱氏体的双层壳型组织结构,未熔化部位的组织为马氏体和铁素体,珠光体球墨铸铁比铁素体球墨铸铁形成的马氏体多。结合区内硬度分布不均匀,球墨铸铁的硬度从基材到结合界面逐渐升高,最高达630HV,Fe-Cr合金平均硬度为510HV。结论 电弧增材制造Fe-Cr合金与球墨铸铁基体冶金结合良好,Fe-Cr合金组织为马氏体和残余奥氏体,有较高的硬度,能满足冲裁模具的性能要求。     

Investigation of the Uncertainty of DIC Under Heterogeneous Strain States with Numerical Tests

Abstract: In this research, numerical 2D digital image correlation (DIC) tests are carried out to assess the uncertainty of DIC under heterogeneous strain states. DIC is implemented to measure the deformation of the numerically deformed images with respect to the undeformed counterparts, which are taken from the real tensile specimens. The tensile specimens are made of three materials, that is, steel DC06, steel DX54D+Z and aluminium alloy Al6016 and cut into three different geometries, namely one standard design and two complex designs. The specimens are all painted manually with random speckle patterns. The original images are deformed by imposed displacement fields, which are obtained by simulating uni‐axial tensile tests of the specimens with finite element analysis (FEA). In this way, the errors sourcing from the hardware of the image system are excluded. According to the geometries of the specimens, homogeneous and heterogeneous strain states are achieved by FEA. The optimum mesh sizes of the models are identified to minimise theirs influence on the imposed fields. The impacts of subset sizes, step sizes and strain window sizes are studied for an optimum correlation. Finally, the influence of the strain state is investigated. It is found that the DIC accuracy and precision decrease under highly heterogeneous strain states.     

Temperature dependence of tensile strength and hardness for nodular cast iron and their mutual correlation

Nodular cast iron has mechanical properties which make it superior to relatively brittle pig cast iron. As a matter of fact, by using appropriate heat treatment processes, the tensile strength of nodular cast iron can be improved to such a degree that its hardness corresponds to that of carbon steels. The main aims in this study are to find the most preferable heat treatment conditions which will yield high strength levels, and to clarify the temperature dependence of mechanical properties for nodular cast iron. The estimation of tensile strength from hardness is also discussed, since tensile tests at elevated temperatures are usually more expensive and time consuming than the hardness tests. Nodular cast irons, having four different microstructures were first prepared by performing the following heat treatments: (1) as-cast, (2) annealed, (3) normalized and (4) bainitized. Tensile property and hardness were then measured for the respective cast irons under elevated temperatures. The temperature dependence of the tensile strength as well as hardness was investigated. It was found that the dependence was well represented by an expression of =₀exp(–BT). Thus results were discussed from a view-point of the reaction rate process. The correlation between tensile strength and hardness was also examined and a significant linearity was found between them. Based on this strict correlation, an estimation procedure of the tensile strength was finally proposed.     

QT400—18L铸件的缩松缺陷对其力学性能的影响

通过静拉伸试验、低温冲击试验、布氏硬度试验和组织形貌分析,研究了QT400—18L球墨铸铁的缩松缺陷对其力学性能的影响。结果表明：缩松使材料的强度和塑性大幅度降低,断裂形式主要为韧性断裂;冲击断裂形式为大量解理和少量韧窝构成的混合断裂;布氏硬度值比标准硬度值至少降低9％;缩松对石墨形态、分布和材料的显微组织无明显影响。     

A comparison of methods for predicting the fatigue life of gray cast iron at elevated temperatures

High temperature fatigue life tests were compared with various life assessment methods for gray cast iron in the cylinder liners of marine engines. The plastic strain range‐based methods such as the universal slopes method, Mitchell's method, Bäumel and Seeger's method, and Ong's method were not predicted well. A method employing tensile energy density, which is defined as the sum of the tensile area of the plastic energy and the elastic energy in the hysteresis loop, was suggested as an improved alternative to the plastic strain range‐based methods. The life estimation equation using tensile energy density predicted well within the 3X scatter band at various temperature ranges of the gray cast iron.     

Influence of additives on the global mechanical behavior and the microscopic strain localization in wood reinforced polypropylene composites during tensile deformation investigated using digital image correlation

The structural integrity of polypropylene (PP) matrix composites reinforced by natural wood fibers is investigated by digital image correlation (DIC) coupled with tensile tests. The use of the material as an alternative construction material requires extensive understanding of its micromechanical properties, which primarily define its performance. Addition of several additives such as coupling agents is common practice for such materials. These ingredients improve the performance of these materials mainly by improvement of the chemical and physical interactions between the nonpolar matrix and the polar wood fibers. These interactions facilitate the transfer of the applied deformation particularly in the interphase region between the polymer matrix and the reinforcing fibers. Such localized changes can influence the performance of the material specially its micromechanical behavior. The DIC via photogrammetry was used to study the spatial distribution of the accumulated plastic surface strain, which is based on pattern recognition of the surface before and after straining. The heterogeneous strain distribution reveals a structural inhomogeneity of the material. The magnitude of local strain was much higher than the global strain, suggesting preferred regions for plastic deformation formed by the microstructure.     

Role of composition heterogeneity on fracture micromechanisms of nodular cast iron

Abstract

The aim of the present study is to explain the role of chemical composition and heterogeneity within the microstructure of nodular cast iron on the micromechanisms of fracture. The heterogeneity in chemical composition is revealed by a thorough study of the microstructure using scanning electron microscopy, Auger electron spectroscopy and colour etching. The ferritic phase surrounding the graphite globules is enriched by silicon and depleted of manganese in the range of micrometres. Maximum manganese concentration is found in regions distant from these particles and in pearlitic regions. Simultaneously, ferritic grain boundaries in the vicinity of the graphite particles are enriched in phosphorus in the nanometer range. This interfacial segregation, reaching nearly 15 at.-%P, is most probably responsible for an embrittlement of these regions and the appearance of intercrystalline decohesion. An elastic-plastic finite element analysis of the ferritic/pearlitic microstructure demonstrates that a heterogeneous microstructure is locally subjected to heterogeneous stresses and strains, which are also expected to affect fracture mechanisms.     

不同含量改性纳米粉体对球墨铸铁拉伸性能的研究

通过冲入法将改性纳米粉体M加入到球墨铸铁中,研究了不同含量的改性纳米粉体M对球墨铸铁组织和拉伸性能的影响。实验结果表明,加入0.01%(质量分数)改性纳米粉体M后,石墨球的综合性能提升最明显,其尺寸减小且变得均匀,数量增加,圆整度提高,晶粒得到细化,珠光体含量降低,铁素体含量增加,拉伸性能得到提升。抗拉强度提高到493.82 MPa,延伸率提高到19.09%。通过断口分析,确定其拉伸断裂的机理为混合式断裂。     

Influence of fiber orientation on global mechanical behavior and mesoscale strain localization in a short glass-fiber-reinforced epoxy polymer composite during tensile deformation investigated using digital image correlation

Advanced polymer composites are used in various fields such as light-weight automobile, aerospace and bio-implant engineering owing to their extraordinary mechanical properties. The various fields of application and the complex microstructures of such materials require better understanding of their micromechanical behavior under external loads. In this work, the tensile testing is coupled with the novel technique of surface displacement mapping via digital image correlation (DIC) is utilized for resolving the mechanical behavior and spatial distribution of the plastic microstrains in an epoxy resin reinforced with 35 wt% short borosilicate glass fibers. The DIC method works by correlating the digital images of surface patterns before and after straining. The material exhibited a pronounced mechanical anisotropy at both macro and mesoscale, which depends on the alignment of the fibers relative to the external load. The underlying microstructure of the material explained formation of strain gradients during evolution of full-field strain fields. The levels of localized strain are higher than the global failure strain of the material. Also, scanning electron microscopy (SEM) on the fracture surfaces revealed the multiple failure mechanisms of the material as a function of the fiber orientation.     

Comparative study on local and global mechanical properties of 2024 T351, 2024 T6 and 5251 O friction stir welds

The effect of the microstructure heterogeneity on the global and local tensile properties of friction stir welded joints in 5251 (O temper) and AA2024 (T351 and T6 tempers) aluminium alloys has been investigated. Micro-tensile tests parallel to the welding direction have been carried out in the regions representative of the main microstructural zones. The digital image correlation technique (DIC) has been used during transverse tensile tests for mapping the strain distribution and to determine the local stress–strain curves. A 3-D finite elements model has been developed to predict the weld behaviour from the tensile curves of the individual regions of the weld.The tensile properties of the 5251 O weld are relatively homogeneous leading to high ductility and fracture in the base material. In contrast, the tensile properties of the various regions of the 2024 T351 and 2024 T6 welds are very heterogeneous and essentially controlled by the state of precipitation. The thermo-mechanically affected zone is the weakest region where the strain localises during a transverse tensile test. The 2024 T6 base material is stronger than the 2024 T351 alloy, leading to a more pronounced strain localisation during transverse tensile tests and a lower overall ductility. Local tensile data obtained by strain mapping are in good agreement with the curves obtained by micro-tensile tests, and these results can be safely used in a finite elements model to predict the behaviour of the overall weld assembly.     

数字图像相关测量钢绞线弹性模量的应用研究

该文利用非接触式数字图像相关方法测量了预应力钢绞线的弹性模量。测量过程中用CCD相机记录不同载荷下钢绞线表面的数字图像,再利用数字图像相关方法对所采集的序列数字图像进行分析从中精确提取不同载荷下钢绞线表面的纵向平均正应变。根据试验机的载荷信息、钢绞线的参考截面积和由数字图像相关方法测量的平均正应变绘制出钢绞线的应力-应...     

On the room-temperature tensile deformation behavior of a cast dual-phase high-entropy alloy CrFeCoNiAl0.7

The microstructure and room-temperature tensile deformation behavior of the cast CrFeCoNiAl0.7 high-entropy alloy (HEA) were studied in details.The cast HEA consisted of a dual-phase structure of 77.3 vol.％ face-centered-cubic (FCC) phase plus 22.7 vol.％ B2 phase,and exhibited excellent room-temperature tensile properties with a high yield strength of 876 MPa,ultimate tensile strength of 1198 MPa and a relatively large elongation to fracture of ～9 ％.Dislocations gliding in the FCC phase governed the plastic deformation at the early stage of room-temperature tensile,and disordered dislocations were to form dislocation walls as the deformation proceeded.With further increase in strain to a high level,the stacking faults were generated through the dissociation of the geometrically necessary dislocations,serving as the potential heterogeneous nucleation sites for the deformation twins.     

Time dependence of mesoscopic strain distribution for triaxial woven carbon-fiber-reinforced polymer under creep loading measured by digital image correlation

This paper presents the time dependence of the mesoscopic strain of a triaxial woven carbon-fiber-reinforced polymer under creep loading measured using digital image correlation (DIC). Two types of DIC techniques were employed for the measurement: conventional subset DIC and mesh DIC. Static tensile and creep tests were carried out, and the time dependence of the mesoscopic strain distribution was investigated by applying these techniques. The ultimate failure of this material is dominated by inter-bundle decohesion caused by relative rigid rotation and relating shear stress. Therefore, these were focused on in the present study. During the creep tests, the fiber directional strain, shear strain, and rotation were monitored using the DIC, and the mechanism for the increase in the specimen’s macro-strain over time was investigated based on the results obtained by the DIC measurement.     

电脉冲对铸态高韧性球墨铸铁凝固组织及性能的影响

对铸态高韧性球墨铸铁QT400-18的凝固过程进行电脉冲处理,电脉冲参数为电压2 600 V,频率0.88 Hz,电容200μF,处理时间15min。通过对比试验可知:电脉冲处理可使铸铁的过冷度相比未处理的升高12K,改善了石墨形核和生长的动力学条件,从而使球状石墨的粒径减小,石墨球数量增加。铸铁经过电脉冲处理,球化率由未处理的平均80%提高到平均91%,石墨球数由平均172/mm~2提高到209/mm~2,石墨不易变态生长,圆整度得到改善。同时,球墨铸铁的凝固组织得到了改善,铁素体数量增加,达到83%,相比未电脉冲处理的试样提高了26.6%,铁素体晶粒小于未处理试样,基体中分布的珠光体数量和片层间距减少,在抗拉强度符合要求的条件下,伸长率提高了4.89%,-233K的冲击功Akv提高了3.56J。     

高温后高强Q690钢材循环加载试验及本构模型研究

为提高金属材性试验的测量精度和测试效率,在传统拉伸试验方法的基础上引入数字图像相关(Digital Image Correlation, DIC)技术,提出相应形变测量理论及方法。基于拉伸试件的颈缩变形特征,提出链式形变测量理论,该理论通过一种跟随表面形状变化而自由变形的柔性链条来表征各阶段的试件形变。进一步通过设置多个连续且等尺寸的DIC二阶链式子区,采用DIC亚像素算法得到任意变形时刻的链式子区角点坐标,并进一步得到沿试件长度方向的柔性离散链形变结果,实现对试件各处应变、颈缩极值点等的求解,从而建立了一套完整的金属拉伸试验DIC辅助测试方法。开展了多个标准金属试件的拉伸试验,通过与引伸仪、靶标图像测量等传统方法对比,验证了该文方法对颈缩效应、弹性模量、极限伸长率、真实应力-应变曲线等金属材性指标具备较高测量精度及有效性,同时该文方法能够实现高度自动化测量,可在金属拉伸试验领域进行工业化推广普及。

     

显微组织对球墨铸铁电阻率的影响

利用双臂电桥测量电阻的方法,研究了石墨球和基体组织对球墨铸铁电阻率的影响。研究结果表明,珠光体和混合基体球墨铸铁的电阻率随石墨球数增加而逐渐提高,而石墨球数对铁素体基体的球墨铸铁电阻率影响不显著;基体组织对球墨铸铁的电阻率有较大影响,随着铁素体量的增加,电阻率逐渐降低。石墨球数量增加导致球墨铸铁电阻率升高的原因是单位体积中石墨球与基体的晶界面积增多。     

Cooling slope casting of cast iron

The aim of the present work is to study the effect of semi‐solid processing using cooling slope method on the microstructure and mechanical properties of grey cast iron. A water cooled castable cement coated steel plate with a variable inclination angle is used to make a mechanical treatment on the semi‐solid flow of grey cast iron. The experiment is repeated for three different pouring temperatures and three inclination angles. The tensile test, hardness test and microstructure examination is used to compare the new properties of the new resulting grey cast irons. The results show that the sharp edged carbon flakes can be refined and the mechanical properties is enhanced. The carbon particles average circularity is increased followed with a decrease in carbon particle size due to the effect of the cooling plate.     

Damage parameters of lamellar grey cast iron in tension

The tensile rupture behaviour of lamellar grey cast iron depends on the overall damage process of the heterogeneous microstructure. It is therefore of interest to apply the continuum damage mechanics concept to this type of material. Two parameters are considered: firstly the damage limit, ₀, and the damage rate,B. Measurements made on a grey cast iron, cast in three different cross-sections, show that these damage parameters may be used to separate the graphite network effects from those of the matrix which interact in the degradation process of the heterogeneous microstructure of lamellar grey cast iron.     

改性纳米SiC粉体强化球墨铸铁的组织和力学性能研究

在生产条件下用改性纳米SiC粉体对球墨铸铁进行了强韧化处理,研究了不同的纳米SiC粉体加入量对球墨铸铁组织和力学性能的影响.结果表明,经改性纳米SiC粉体强韧化后,球墨铸铁中的石墨球尺寸减小,圆整度提高,铁素体含量增多,球墨铸铁的韧性提高.断口分析结果表明,经过强韧化处理后,球墨铸铁的断裂方式为脆性韧性混合断裂.