An analytical approach to predict web-warping and longitudinal strain in flexible roll formed sections of variable width

To reduce weight and improve passenger safety there is an increased need in the automotive industry to use Ultra High Strength Steel (UHSS) for structural and crash components. However, the application of UHSS is restricted by their limited formability and the difficulty of forming them in conventional stamping. An alternative method of manufacturing structural auto body parts from UHSS is the flexible roll forming process, which allows the manufacture of metal sheet with high strength and limited ductility into complex and weight-optimized components. One major problem in the flexible roll forming of UHSS is the web-warping defect, which is the deviation in height of the web area over the length of the profile. It has been shown that web-warping is strongly dependant to the permanent longitudinal strain formed in the flange of the part. Flexible roll forming is a continuous process with many roll stands, which makes numerical analysis extremely time intensive and computationally expensive. An analytical model of web-warping is therefore critical to improve design efficiency during the early process design stage before FEA is applied. This paper establishes for the first time an analytical model for the prediction of web-warping for the flexible roll forming of a section with variable width. The model is based on evaluating longitudinal edge strain in the flange of the part. This information is then used in combination with a simple geometrical model to investigate the relationship between web-warping and longitudinal strain with respect to process parameters.

Modeling of shear ductile fracture considering a changeable cut-off value for stress triaxiality

 A macroscopic ductile fracture criterion is proposed based on micro-mechanism analysis of nucleation, growth and shear coalescence of voids from experimental observation of fracture surfaces. The proposed ductile fracture model endows a changeable cut-off value for the stress triaxiality to represent effect of micro-structures, the Lode parameter, temperature, and strain rate on ductility of metals. The proposed model is used to construct fracture loci of AA 2024- T351. The constructed fracture loci are compared with experimental data covering wide stress triaxiality ranging between –0.5 and 1.0. The comparison suggests that the proposed model can provide a satisfactory prediction of ductile fracture for metals from compressive upsetting tests to plane strain tension with slanted fracture surfaces. Moreover, it is expected that the proposed model reasonably describes ductile fracture behavior in high velocity perforation simulation since a reasonable cut-off value for the stress triaxiality is coupled with the proposed ductile fracture criterion.

Effect of temperature on mechanical behaviour of high manganese TWIP steel

The aim of the present study was to investigate the role of deformation temperature on the active deformation mechanisms in a 0.6C-18Mn-1.5Al (wt%) TWIP steel. The tensile testing was performed at different temperatures, ranging from ambient to 400°C at a constant strain rate of 10-3 S-1. The microstructure characterization was carried out using a scanning electron microscopy. The deformation temperature revealed a significant effect on the active deformation mechanisms (i.e. slip versus twinning), resulting in different microstructure evolution and mechanical properties. At the room temperature, the mechanical twinning was the dominant deformation mechanism, enhancing both the strength and ductility. Dynamic strain aging (DSA) effect was observed at different deformation temperatures, though it was more pronounced at higher temperatures. The volume fraction of deformation twins significantly reduced with an increase in the deformation temperature, deteriorating the mechanical behavior. There was a transition temperature (~300°C), above which the mechanical twinning was hardly observed in the microstructure even at fracture, resulting in low ductility and strength. The current observation can be explained through the change in the stacking fault energy with the deformation temperature. © (2014) Trans Tech Publications, Switzerland.

Effect of alloying and extrusion temperature on the microstructure and mechanical properties of Mg-Zn and Mg-Zn-RE alloys

Extruded Mg-Zn-RE alloys have been shown to exhibit excellent combinations of yield strength and ductility, but it is not completely clear how adding rare earth metals to Mg-Zn alters the microstructure and affects the mechanical properties. Microstructural changes and the resulting mechanical properties from changes in composition and extrusion temperature have been investigated for Mg-. x Zn-. y RE (. x=2.5 and 5. wt.%, y=0 and 1. wt. %, and RE=Gd and Y) alloys. Adding RE to Mg-Zn increased the strength and reduced the ductility, while increasing the zinc concentration in the Mg-Zn-RE alloys had the reverse effect.

Characterization of microstructures and tensile properties of TRIP-aided steels with different matrix microstructure

Three different heat treatment processes have been proposed as a fundamental method to produce three kinds of TRIP-aided steels with polygonal ferritic matrix (F-TRIP), bainitic matrix (B-TRIP) and martensitic matrix (M-TRIP) in a newly designed low alloy carbon steel. By means of dilatometry study and detailed characterization, the relationships among transformation, microstructure and the resulting mechanical behavior were compared and analyzed for the three cases. The work hardening of the samples was evaluated by calculating the instantaneous n value as a function of strain. The M-TRIP sample exhibits the highest strength with the highest work hardening rate at low strains and subsequent rapid descending at high strains. In contrast, the B-TRIP sample has relatively high continuously constant work hardening behavior over strain levels greater than 0.067. The difference in work hardening behavior corresponds directly to the rate of the retained austenite-martensitic transformation during straining, which can be attributed to the carbon content, the morphology of the retained austenite and the matrix microstructure in the respective TRIP-aided samples. © 2014 Elsevier B.V.

Properties of bio-based polymer nylon 11 reinforced with short carbon fiber composites

In this work, micro-composite materials were produced by incorporating 3-mm long reclaimed short carbon fibers into bio-based nylon 11 via melt compounding. A systematic fiber length distribution analysis was performed after the masterbatching, compounding and an injection moulding processes using optical microscopy images. It was found that the large majority of the fibers were within the 200-300 μm in length range after the injection moulding process. The mechanical (flexural and tensile), thermo-mechanical, and creep properties of the injection moulded materials are reported. We found that an enhancement in flexural and Young's modulus of 25% and 14%, respectively, could be attained with 2 wt% carbon fiber loading whilst no significant drawback on the ductility and toughness of the matrix was observed. The creep resistance and recovery of the nylon 11, tested using dynamic mechanical thermal analysis at room temperature and 65°C, was significantly improved by up to 30% and 14%, respectively, after loading with carbon fiber. This work provides an insight into the property improvement of the bio-based polymer nylon 11 using a small amount of a reclaimed engineered material. © 2014 Society of Plastics Engineers.

Strain partitioning in dual-phase steels containing tempered martensite

Tempering has been used as a method to develop a range of dual phase steels with the same martensite morphology and volume fraction, but containing phases with different relative strengths. These steels were used to examine the strain partitioning between the two constituent phases experimentally through mechanical testing and numerically through finite element modelling. It was found that increasing the differential in strength between the two phases not only produces regions of high strain, but also regions of low strain. On average, a larger difference in strength between the phases increased the strain carried by the softer phase. There was no discernible preferential strain localisation to the ferrite/martensite interface, with the regions of strain localisation being determined by the morphology of the microstructure. A direct correlation between the average strain in the ferrite, and the measured ductility has been found. © 2014 Elsevier B.V.

Multi-phase microstructure design of a novel high strength TRIP steel through experimental methodology

The multi-phase structure of a novel low-alloy transformation induced plasticity (TRIP) steel was designed through experimental analysis. The evolutions of both microstructure and mechanical properties during the two-stage heat treatment were analyzed. The phase transformations during the intercritical annealing and the isothermal bainitic transformation were investigated by means of dilatometry. It was shown that two types of C diffusion were detected during intercritical annealing and a complex microstructure was formed after heat treatment. The processing parameters were selected in such a way to obtain microstructures with systematically different volume fractions of ferrite, bainite and retained austenite. The volume fractions of ferrite and retained austenite were found to be two main factors controlling the ductility. Furthermore, a high volume fraction of C-rich retained austenite, which was stabilized at room temperature, was the origin of a TRIP effect. The resulting material demonstrates a significant improvement in the ultimate tensile strength (1077. MPa) with good uniform elongation (22.5%), as compared to conventional TRIP steels. © 2014 Elsevier B.V.

The microstructure and properties of energetically deposited carbon nitride films

The intrinsic stress, film density and nitrogen content of carbon nitride (CNx) films deposited from a filtered cathodic vacuum arc were determined as a function of substrate bias, substrate temperature and nitrogen process pressure. Contour plots of the measurements show the deposition conditions required to produce the main structural forms of CNx including N-doped tetrahedral amorphous carbon (ta-C:N) and a variety of nitrogen containing graphitic carbons. The film with maximum nitrogen content (~ 30%) was deposited at room temperature with 1.0 mTorr N2 pressure and using an intermediate bias of - 400 V. Higher nitrogen pressure, higher bias and/or higher temperature promoted layering with substitutional nitrogen bonded into graphite-like sheets. As the deposition temperature exceeded 500 °C, the nitrogen content diminished regardless of nitrogen pressure, showing the meta-stability of the carbon-nitrogen bonding in the films. Hardness and ductility measurements revealed a diverse range of mechanical properties in the films, varying from hard ta-C:N (~ 50 GPa) to softer and highly ductile CN x which contained tangled graphite-like sheets. Through-film current-voltage characteristics showed that the conductance of the carbon nitride films increased with nitrogen content and substrate bias, consistent with the transition to more graphite-like films. © 2014 Elsevier B.V.

Finite element analysis of residual stresses in metallic coatings through a compound casting

Al and Mg alloys are widely used in industry as main lightweight alloys. They have excellent properties, such as low density, high ductility, and high specific strength, and so on. Generally speaking, Mg alloys are better than Al alloys. However the corrosion of Mg alloys is much more difficult to control compared Al alloys. Therefore to combine these two lightweight alloys, a composite-like structure is an ideal solution since Al alloys can be used as protective coatings for Mg alloys. Compound casting is a realistic technique to get this coating system. In the current study, we numerically study the compound casting using finite element method (FEM) to make these two alloys, a composite-like structure, satisfy requirements to resist corrosion required from industry, in which the aluminum layer is acting as a protective coating for the magnesium substrate. Several finite element models have been developed by using the birth and death element technique and we focus on compound casting-induced residual stresses in the compounded structure. The numerical results obtained from the proposed finite element models show the distribution profiles of thermal residual stresses. We found the major factors influencing the residual stresses are the temperature to pre-heating the Al substrate and the thickness of Mg deposits. © (2014) Trans Tech Publications, Switzerland.

Severe plastic deformation of TWIP steel

The severe plastic deformation of a Twinning Induced Plasticity (TWIP), 0.61C-22.3Mn-0.19Si-0.14Ni-0.27Cr (wt. %) steel by Equal Channel Angular Pressing (ECAP) at elevated temperatures was used to study the deformation mechanism as a function of accumulated strain and processing parameters. The relationship between the microstructures after different deformation schedules of ECAP at the temperatures of 200, 300 and 400oC, strain hardening behavior and mechanical properties was studied. The best balance between strength and ductility (1702 MPa and 24%) was found after 2 passes at 400oC and 300oC of ECAP. It was due to the formation of deformation microbands and twins in the microstructure. The twinning was observed after all deformation schedules except after 1 pass at 400oC. The important finding was the formation of twins in the ultrafine grains. Moreover, the stacking faults were observed in the subgrains with the size of 50nm. It is also worth mentioning the formation of nano- twins within the micro-twins at the same time. It was found that the deformation schedule affects the dislocation substructure with formation of deformation bands, cells, subgrains, two variants of twins that, in turn, influence the strain-hardening behavior and mechanical properties. Keywords: Twinning Induced Plasticity steels; Equal Channel Angular Pressing; mechanical properties; transmission electron microscopy; micro/nano twins; dislocation substructure.

On low temperature bainite transformation characteristics using in-situ neutron diffraction and atom probe tomography

In-situ neutron diffraction was employed to monitor the evolution of nano-bainitic ferrite during low temperature isothermal heat treatment of austenite. The first 10 peaks (austenite, γ and ferrite, α) were monitored during austenization, homogenization, rapid cooling and isothermal holding at 573 K. Changes in the α-110 and γ-111 peaks were analysed to determine the volume fraction changes and hence the kinetics of the phase transformation. Asymmetry and broadening in the α-200 and γ-200 peaks were quantified to lattice parameter changes due to carbon redistribution as well as the effects of size and dislocation density. Atom Probe Tomography was used to confirm that, despite the presence of 1.5 mass % Si, carbide formation was evident. This carbide formation is the cause of poor ductility, which is lower than expected in such steels.

Kinetics of γ-Mg17Al12 phase dissolution and its effect on room temperature tensile properties in as-cast AZ80 magnesium alloy

As-cast AZ80 magnesium alloy consists of α-Mg, eutectic product of α-Mg and γ-Mg17Al12, with the latter present in the form of partially and fully divorce eutectic. There occurs dissolution of harder γ-Mg17Al12 phase during homogenization treatment at 400 ° and 439 °C. The proportion of the α-Mg and γ-Mg17Al12 phase was varied by solutionizing the alloy for various lengths of time at these temperatures, in order to investigate the kinetics of phase transformation and to evaluate the effect of phase proportion, size and morphology on room temperature tensile properties. It was found that the yield strength decreases with the increase in solutionizing temperature from 400° to 439 °C and at the same time, ductility in general increases with the increasing solutionizing temperature. The variation in tensile properties and the nature of fractographs were analyzed in terms of the effects of microstructure. © (2014) Trans Tech Publications, Switzerland.

Thermo-mechanical processing of TRIP-aided steels

The effects of the partial replacement of Si with Al and the addition of P on the microstructure and mechanical properties of experimental TRIP-aided steels subjected to different thermo-mechanical cycles were studied. Based on the available literature and thermodynamics-based calculations, three steels with different compositions were designed to obtain optimum results from a relatively low number of experiments. Different combinations of microstructure were developed through three different kinds of thermo-mechanical-controlled processing (TMCP) routes, and the corresponding tensile properties were evaluated. The results indicated that partial replacement of Si with Al improved the strength-ductility balance along with providing an improved variation in the incremental change in the strain-hardening exponent. However, the impact of the P addition was found to depend more on the final microstructure obtained by the different TMCP cycles. It has also been shown that an increase in the volume fraction of the retained austenite ($$ V_{{\gamma_{\text{ret}} }} $$Vγret) or its carbon content ($$ C_{{\gamma_{\text{ret}} }} $$Cγret) resulted in an improved strength-ductility balance, which can be attributed to better exploitation of the TRIP effect.

Microstructure and texture evolution during tensile deformation of symmetric/asymmetric-rolled low carbon microalloyed steel

The deformation and fracture mechanisms of a low carbon microalloyed steel processed by asymmetric rolling (AsR) and symmetric rolling (SR) were compared by microstructural and texture evolutions during uniaxial tensile deformation. A realistic microstructure-based micromechanical modeling was involved as well. AsR provides more effective grain refinement and beneficial shear textures, leading to higher ductility and extraordinary strain hardening with improved yield and ultimate tensile stresses as well as promoting the occurrence of ductile fracture. This was verified and further explained by means of the different fracture modes during quasi-static uniaxial deformation, the preferred void nucleation sites and crack propagation behavior, and the change in the dislocation density based on the kernel average misorientation (KAM) distribution. The equivalent strain/stress partitioning during tensile deformation of AsR and SR specimens was modeled based on a two-dimensional (2D) representative volume element (RVE) approach. The trend of strain/stress partitioning in the ferrite matrix agrees well with the experimental results.