Twinning and the ductility of magnesium alloys Part II. “Contraction” twins

Magnesium and its alloys do not in general undergo the same extended range of plasticity as their competitor structural metals. The present work presents part II of a study that examines some of the roles deformation twinning might play in the phenomenon. A series of tensile and compression tests results are reported for common wrought alloys: AZ31, ZK60 and ZM20. These data are combined with EBSD analysis and simple flow stress models to argue the following: (i) that “contraction” double twinning (which enables contraction along the c axis) can decrease the uniform elongation, and (ii) that compression double twinning can also account for shear failure at low strains. The last of these is described as a combined consequence of strain softening of the continuum and the local generation of twin sized voids.

Properties of a carbon-fibre composite modified by electrospun poly (vinylidene fluoride)

The interlaminar toughening of a carbon-fibre reinforced composite by incorporation of electrospun polyvinylidene fluoride (PVDF) nanofibrous membranes was explored in this work. The nanofibres were electrospun directly onto commercial pre-impregnated carbon fibre materials under optimised conditions and PVDF was found to primarily crystallise in its β phase polymorphic form. There is strong evidence from DMTA analysis to suggest that a partial miscibility between the amorphous phases of the PVDF nanofibres and the epoxy exists. The improved plastic deformation at the crack tip after inclusion of the nanofibres was directly translated to a 57% increase in the mode II interlaminar fracture toughness (in-plane shear failure). Conversely, the fracture toughness in mode I (opening failure) was slightly lower than the reference by approximately 20%, and the results were interpreted from the complex micromechanisms of failure arising from the changes in polymorphism of the PVDF.

Toughening of a carbon-fibre composite using electrospun poly(Hydroxyether of Bisphenol A) nanofibrous membranes through inverse phase separation and inter-domain etherification

The interlaminar toughening of a carbon fibre reinforced composite by interleaving a thin layer (~20 microns) of poly(hydroxyether of bisphenol A) (phenoxy) nanofibres was explored in this work. Nanofibres, free of defect and averaging several hundred nanometres, were produced by electrospinning directly onto a pre-impregnated carbon fibre material (Toray G83C) at various concentrations between 0.5 wt % and 2 wt %. During curing at 150 °C, phenoxy diffuses through the epoxy resin to form a semi interpenetrating network with an inverse phase type of morphology where the epoxy became the co-continuous phase with a nodular morphology. This type of morphology improved the fracture toughness in mode I (opening failure) and mode II (in-plane shear failure) by up to 150% and 30%, respectively. Interlaminar shear stress test results showed that the interleaving did not negatively affect the effective in-plane strength of the composites. Furthermore, there was some evidence from DMTA and FT-IR analysis to suggest that inter-domain etherification between the residual epoxide groups with the pendant hydroxyl groups of the phenoxy occurred, also leading to an increase in glass transition temperature (~7.5 °C).

Mechanical Behavior of Nano-crystalline Metallic Thin Films and Multilayers Under Microcompression

Microcompression tests were performed to determine the mechanical behavior of nano-crystalline Cu/Fe and Fe/Cu multilayers, as well as monolithic Cu and Fe thin films. The results show that the micropillars of pure Cu thin film bulge out under large compressive strains without failure, while those of pure Fe thin film crack near the top at low compressive strains followed by shear failure. For Cu/Fe and Fe/Cu multilayers, the Cu layers accommodate the majority of plastic deformation, and the geometry constraints imposed by Fe layers exaggerates the bulging in the Cu layers. However, the existence of ductile Cu layers does not improve the overall ductility of Cu/Fe and Fe/Cu multilayers. Cracking in the Fe layers directly lead to the failure of the multilayer micropillars, although the Cu layers have very good ductility. The results imply that suppressing the cracking of brittle layers is more important than simply adding ductile layers for improving the overall ductility of metallic multilayers.

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.

Prediction of failure in bending of an aluminium sheet alloy

This work is dedicated to numerical prediction of the bending of thin aluminium alloy sheets, with a focus on the material parameter identification and the prediction of rupture with or without pre-strains in tension prior to bending. The experimental database consists of i) mechanical tests at room temperature, such as tension and simple shear, performed at several orientations to the rolling direction and biaxial tension ii) air bending tests of rectangular samples after (or not) pre-straining in tension. The mechanical model is composed of the Yld2004-18p anisotropic yield criterion (Barlat et al. [3]) associated with a mixed hardening rule. The material parameters (altogether 21) are optimized with an inverse approach, in order to minimize the gap between experimental data and model predictions. Then, the Hosford-Coulomb rupture criterion is used in an uncoupled way, and the parameters are determined from tensile tests, both uniaxial and biaxial, with data up to rupture. In a second step, numerical simulations of the bending tests are performed, either on material in its original state or after pre-straining in tension, with pre-strain magnitudes increasing from 0.19 up to 0.3. The comparisons are performed on different outputs: load evolution, strain field and prediction of the rupture. A very good correlation is obtained over all the tests, in the identification step as well as in the validation one. Moreover, the fracture criterion proves to be successful whatever the amount of pre-strain may be. A convincing representation of the mechanical behavior at room temperature for an aluminium alloy is thus obtained.

A study on truss bolt mechanism in controlling stability of underground excavation and cutter roof failure

The truss bolt reinforcement system has been used in controlling the stability of underground excavations in severe ground conditions and cutter roof failure in layered rocks especially in coal mines. In spite of good application reports, working mechanism of this system is largely unknown and truss bolts are predominantly designed based on past experience and engineering judgement. In this study, the reinforcing effect of the truss bolt system on an underground excavation in layered rock is studied using non-linear finite element analysis. Different indicators are defined to evaluate the reinforcing effects of the truss bolt system. Using these indicators one can evaluate the effects of a reinforcing system on the deformation, loosened area, failure prevention, horizontal movement of the immediate layer, shear crack propagation and cutter roof failure of underground excavations. Effects of truss bolt on these indicators reveal the working mechanism of the truss bolt system. To illustrate the application of these indicators, a comparative study is conducted between three different truss bolt designs. It is shown that the design parameters of truss bolt systems, including tie-rod span, length, and angle of the bolts can have significant effects on the reinforcing capability of the system.