The prediction of process-induced deformation in a thermoplastic composite in support of manufacturing simulation

Digital manufacturing techniques can simulate complex assembly sequences using computer-aided design-based, as-designed' part forms, and their utility has been proven across several manufacturing sectors including the ship building, automotive and aerospace industries. However, the reality of working with actual parts and composite components, in particular, is that geometric variability arising from part forming or processing conditions can cause problems during assembly as the as-manufactured' form differs from the geometry used for any simulated build validation. In this work, a simulation strategy is presented for the study of the process-induced deformation behaviour of a 90 degrees, V-shaped angle. Test samples were thermoformed using pre-consolidated carbon fibre-reinforced polyphenylene sulphide, and the processing conditions were re-created in a virtual environment using the finite element method to determine finished component angles. A procedure was then developed for transferring predicted part forms from the finite element outputs to a digital manufacturing platform for the purpose of virtual assembly validation using more realistic part geometry. Ultimately, the outcomes from this work can be used to inform process condition choices, material configuration and tool design, so that the dimensional gap between as-designed' and as-manufactured' part forms can be reduced in the virtual environment.

Evaluation of Cyclic Deformation Behavior of Laser-welded Shape Memory NiTi Alloys at Different Working Temperatures

Post-weld heat-treatment (PWHT) has been established as one of the cost-effective ways to improve the functional properties, namely shape memory and super-elastic effects (SME and SE), of laser-welded NiTi alloys. However, the functional performance of the laser-welded joint at different working temperatures has not been explored yet. The purpose of this study is to investigate the effect of different working temperatures on the functional properties of the laser-welded NiTi alloys before and after PWHT by applying cyclic deformation tests. Two laser-welded samples: as-welded and heat-treated sample (after PWHT at 350 oC or 623 K) were tested in this work at room temperature, 50 oC (or 323 K) and 75 oC (or 348 K) respectively. The samples were cyclically loaded and unloaded for 10 cycles up to 4 % strain. The critical stress to induce the martensitic transformation and the residual strain after the cyclic tests were recorded. The results indicate that the heat-treated sample exhibited better functional properties than the as-welded sample at room temperature and 50 oC (or 323 K). However, both the as-welded and heat-treated samples failed in the cyclic tests at 75 oC (or 348 K). These findings are important to determine the feasible working temperature range for the laser-welded NiTi components to exhibit desirable functional properties in engineering applications involving cyclic loading.

Progressive deformation of glacial till due to viscoplastic straining and pore pressure variation

The stress regime in a cutting (slope) is complex, with different principle stresses acting in different directions along the potential failure plane. For example, stresses may be primarily in extension near the toe and in compression near the crest of a slope. Cuttings in heavily overconsolidated clays are known to be susceptible to progressive failure which usually starts at the toe of the slope. Softening and the development of rupture surfaces have been observed in the field and are well documented for London Clays. However, this failure mechanism is yet to be established for glacial tills. To better understand the progressive failure mechanism, this paper discusses a series of laboratory tests conducted on reconstituted glacial till samples from Northern Ireland. Initial observations indicate that, a soil with insitu stress states between 80-90% of peak strength may undergo significant viscoplastic straining as a result of the combination of pore-pressure cycling and elevated stress level.

Hot deformation characteristics of a nitride strengthened martensitic heat resistant steel

Constitutive equations including an Arrhenius term have been applied to analyze the hot deformation behavior of a nitride-strengthened (NS) martensitic heat resistant steel in temperature range of 900–1200 °C and strain rate range of 0.001–10 /s. On the basis of analysis of the deformation data, the stress–strain curves up to the peak were divided into four regions, in sequence, representing four processes, namely hardening, dynamic recovery (DRV), dynamic strain induced transformation (DSIT), and dynamic recrystallization (DRX), according to the inflection points in ∂θ/∂σ∂θ/∂σ and ∂(∂θ/∂σ)/∂σ∂(∂θ/∂σ)/∂σ curves. Some of the inflection points have their own meanings. For examples, the minimum of ∂θ/∂σ∂θ/∂σ locates the start of DRV and the maximum of it indicates the start of DRX. The results also showed that the critical strain of DRX was sensitive to ln(Z) below 40, while the critical stress of DRX was sensitive to it above 40. The final microstructures under different deformation conditions were analyzed in terms of softening processes including DRV, DRX, metadynamic crystallization (MDRX) and DSIT.

Analysis of deformation behavior and workability of advanced 9Cr-Nb-V ferritic heat resistant steels

Hot compression tests were carried out on 9Cr–Nb–V heat resistant steels in the temperature range of 600–1200 °C and the strain rate range of 10−2–100 s−1 to study their deformation characteristics. The full recrystallization temperature and the carbon-free bainite phase transformation temperature were determined by the slope-change points in the curve of mean flow stress versus the inverse of temperature. The parameters of the constitutive equation for the experimental steels were calculated, including the stress exponent and the activation energy. The lower carbon content in steel would increase the fraction of precipitates by increasing the volume of dynamic strain-induced (DSIT) ferrite during deformation. The ln(εc) versus ln(Z) and the ln(σc) versus ln(Z) plots for both steels have similar trends. The efficiency of power dissipation maps with instability maps merged together show excellent workability from the strain of 0.05 to 0.6. The microstructure of the experimental steels was fully recrystallized upon deformation at low Z value owing to the dynamic recrystallization (DRX), and exhibited a necklace structure under the condition of 1050 °C/0.1 s−1 due to the suppression of the secondary flow of DRX. However, there were barely any DRX grains but elongated pancake grains under the condition of 1000 °C/1 s−1 because of the suppression of the metadynamic recrystallization (MDRX).

A low-cost digital image correlation technique for characterising the shear deformation of fabrics for draping studies

A novel digital image correlation (DIC) technique has been developed to track changes in textile yarn orientations during shear characterisation experiments, requiring only low-cost digital imaging equipment. Fabric shear angles and effective yarn strains are calculated and visualised using this new DIC technique for bias extension testing of an aerospace grade, carbon-fibre reinforcement material with a plain weave architecture. The DIC results are validated by direct measurement, and the use of a wide bias extension sample is evaluated against a more commonly used narrow sample. Wide samples exhibit a shear angle range 25% greater than narrow samples and peak loads which are 10 times higher. This is primarily due to excessive yarn slippage in the narrow samples; hence, the wide sample configuration is recommended for characterisation of shear properties which are required for accurate modelling of textile draping.

Stress and Strain Distributions During Compressive Deformation of Titanium Alloy Affected by Microstructure

In the research of the microstructural influence on dynamic compression, an assumption that the α and the β phases in titanium alloys were linearly strengthened was proposed, and a two-dimensional model using ANSYS (ANSYS, Inc., Canonsburg, PA) focusing on the role of microgeometrical structure was developed. By comparing the stress and strain distributions of different microstructures, the roles of cracks and phase boundaries in titanium compression were studied.

Characterization and structure–property relationship of melt-mixed high density polyethylene/multi-walled carbon nanotube composites under extensional deformation

Melt-mixed high density polyethylene (HDPE)/multi-walled carbon nanotube (MWCNT) nanocomposites with 1–10 wt% MWCNTs were prepared by twin screw extrusion and compression moulded into sheet form. The compression moulded nanocomposites exhibit a 112% increase in modulus at a MWCNT loading of 4 wt%, and a low electrical percolation threshold of 1.9 wt%. Subsequently, uniaxial, sequential (seq-) biaxial and simultaneous (sim-) biaxial stretching of the virgin HDPE and nanocomposite sheets was conducted at different strain rates and stretching temperatures to investigate the processability of HDPE with the addition of nanotubes and the influence of deformation on the structure and final properties of nanocomposites. The results show that the processability of HDPE is improved under all the uniaxial and biaxial deformation conditions due to a strengthened strain hardening behaviour with the addition of MWCNTs. Extensional deformation is observed to disentangle nanotube agglomerates and the disentanglement degree is shown to depend on the stretching mode, strain rate and stretching temperatures applied. The disentanglement effectiveness is: uniaxial stretching < sim-biaxial stretching < seq-biaxial stretching, under the same deformation parameters. In sim-biaxial stretching, reducing the strain rate and stretching temperature can lead to more nanotube agglomerate breakup. Enhanced nanotube agglomerate disentanglement exhibits a positive effect on the mechanical properties and a negative effect on the electrical properties of the deformed nanocomposites. The ultimate stress of the composite containing 4 wt% MWCNTs increased by ∼492% after seq-biaxial stretching, while the resistivity increased by ∼1012 Ω cm.

Improved model for interfacial stresses accounting for the effect of shear deformation in plated beams

A significant increase in strength and performance of reinforced concrete, timber and metal beams may be achieved by adhesively bonding a fibre reinforced polymer composite, or metallic such as steel plate to the tension face of a beam. One of the major failure modes in these plated beams is the debonding of the plate from the original beam in a brittle manner. This is commonly attributed to the interfacial stresses between the adherends whose quantification has led to the development of many analytical solutions over the last two decades. The adherends are subjected to axial, bending and shear deformations. However, most analytical solutions have neglected the effect of shear deformation in adherends. Few solutions consider this effect approximately but are limited to one or two specific loading conditions. This paper presents a more rigorous solution for interfacial stresses in plated beams under an arbitrary loading with the shear deformation of the adherends duly considered in closed form using Timoshenko’s beam theory. The solution is general to linear elastic analysis of prismatic beams of arbitrary cross section under arbitrary loading with a plate of any thickness bonded either symmetrically or asymmetrically with respect to the span of the beam.

Geoquímica dos granitóides de Aguiar da Beira, norte de Portugal

A área de Aguiar da Beira está integrada nos terrenos autóctones da Zona Centro-ibérica e é constituída essencialmente por rochas granitóides variscas instaladas durante e após a terceira fase de deformação (D3). As relações de campo mostram que estes granitóides intruíram formações metassedimentares de idade proterozóica superior-câmbrica e as sequências do Ordovícico e do Carbónico do sinclinal Porto-Sátão, cujo extremo SE aflora na área de estudo. Com base na cartografia publicada e nos dados de campo colhidos no âmbito deste trabalho, foi possível individualizar oito intrusões distintas: o granodiorito -granito biotítico de Sernancelhe, o granito gnaissoso de duas micas, o granito moscovítico-biotítico de Vila Nova de Paiva, o granodiorito-granito biotítico-moscovítico de Lagares e os granitos de Touro (biotítico-moscovítico), Aguiar da Beira (moscovítico-biotítico), Pera Velha / Vila da Ponte (biotítico-moscovítico) e Rei Mouro (moscovítico-biotítico). A presença de encraves microgranulares em cinco dos granitóides estudados sugere que os processos de mistura de magmas desempenharam um papel importante na sua petrogénese. As datações U-Pb obtidas em zircões e monazites durante o presente estudo permitiram subdividir os granitóides de Aguiar da Beira em três grupos, de acordo com as suas relações com a terceira fase de deformação (D3): granitóides sin-tectónicos (Sernancelhe e granito gnaissoso; 322-317 Ma), tardi-tectónicos (Vila Nova de Paiva, Lagares e Touro; 308-306 Ma), e tardi- a pós-tectónicos (Aguiar da Beira, Pera Velha / Vila da Ponte e Rei Mouro; 303297 Ma). As assinaturas geoquímicas de elementos maiores e traço dos granitóides estudados, em conjunto com os dados isotópicos Sr-Nd e δ18 (rocha total e zircão) apontam para uma contribuição significativa de protólitos crustais na génese destes magmas. Á excepção do granito gnaissoso, todos os granitóides possuem um carácter transicional entre os granitos do tipo I e do tipo S, o que apoiado pelos dados de geoquímica de rocha total e isotópica, e pela presença de encraves microgranulares de composição mais máfica presentes em muitos deles, indicia uma forte intervenção de processos de hibridização de líquidos de proveniência distinta (crustais e mantélicos), em diferentes proporções, na sua origem. Pelo contrário, as características geoquímicas e isotópicas do granito gnaissoso revelam claras afinidades com os granitos do tipo S, e sugerem que tenha derivado da anatexia de fontes exclusivamente supracrustais. No entanto, parte da variabilidade geoquímica e isotópica observada em todos os granitóides estudados só poderá ser explicada pela actuação de processos de cristalização fraccionada, especialmente intensos no caso do granito gnaissoso e dos granitos tardi- a PÓS-D3.

Relações petrogénicas entre o complexo gnáissico migmático e o granito de Banabuiú (Nordeste do Brasil)

A região de Banabuiú situa-se no Domínio Ceará Central, na porção setentrional da Província Borborema, um dos cinturões orogénicos formados durante o evento Brasiliano/Pan-Africano no final do Neoproterozóico. As duas unidades litológicas principais presentes na área são: o complexo gnáissicomigmatítico (metapelitos e metagrauvaques) e granitóides brasilianos. Para além das formações paraderivadas, no substrato da região também foi identificado um conjunto de rochas ortoderivadas, até então não individualizado na cartografia existente. Tanto a sequência paraderivada, como os materiais ortoderivados, foram intensamente afectados por metamorfismo regional da fácies granulítica durante a Orogenia Brasiliana, que atingiu as condições de fusão parcial, gerando migmatitos com um amplo espectro de morfologias. Estes migmatitos apresentam estruturas dominantemente estromáticas, embora localmente se tenham identificado também corpos irregulares de diatexitos de tipo“schlieren”, “schollen” e “maciço (s.s)”, indicando que o processo de migmatização culminou com a produção de maiores quantidades de fundido. Em termos tectónicos, o basamento da região regista os efeitos de três fases de deformação, embora as estruturas concordantes à D3 sejam dominantes e obliterem, em muitos casos, as anisotropias anteriores. A maior parte dos fundidos anatécticos parece ter sido produzida durante tectónica transcorrente D3. No entanto, as condições metamórficas para o início da fusão parcial parece ter sido atingidas antes, durante a D2, já que também existem leucossomas, embora em proporções reduzidas, associados com as estruturas desta fase. A grande quantidade de volumes de leucossomas / veios leucocráticos encontrados na região, está relacionada com a actuação da zona de cisalhamento de Orós e parece corresponder a fundidos anatécticos gerados em níveis mais profundos que foram injectados nas sequências orto- e para-derivadas, devido a notória escassez de leucossomas “in situ” nestas rochas. A presença de fluidos aquosos injectados no complexo migmatítico de Banabuiú terá proporcionado a re-hidratação e retrogradação das rochas hospedeiras, evidenciada, essencialmente, pela presença de moscovite tardia, amplamente distribuída nos metassedimentos e ortognaisses, sobretudo nas zonas próximas aos leucossomas e veios leucocráticos. Dados isotópicos apontam que as rochas da região de Banabuiú apresentam valores fortemente negativos de εNdt e positivos de εSrt sugerindo um significativo envolvimento de materiais supracrustais do grupo Acopiara na formação do complexo migmatítico e na petrogénese do maciço granítico de Banabuiú e o marcado fraccionamento isotópico Sm-Nd observado nalguns dos leucossomas analisados indica que os líquidos anatécticos que lhes deram origem resultaram de processos de fusão em desequilíbrio, em condições anidras, e foram rapidamente extraídos da área-fonte, comprovando o carácter alóctone dos veios leucocráticos intercalados nos ortognaisses e paragnaisses de Banabuiú.

Severe plastic deformation of Al–Zn alloys

In this work, the R&D work mainly focused on the mechanical and microstructural analysis of severe plastic deformation (SPD) of Al–Zn alloys and the development of microstructure–based models to explain the observed behaviors is presented. Evolution of the microstructure and mechanical properties of Al–30wt% Zn alloy after the SPD by the high–pressure torsion (HPT) has been investigated in detail regarding the increasing amount of deformation. SPD leads to the gradual grain refinement and decomposition of the Al–based supersaturated solid solution. The initial microstructure of the Al–30wt% Zn alloy contains Al and Zn phases with grains sizes respectively of 15 and 1 micron. The SPD in compression leads to a gradual decrease of the Al and Zn phase grain sizes down to 4 microns and 252 nm, respectively, until a plastic strain of 0.25 is reached. At the same time, the average size of the Zn particles in the bulk of the Al grains increases from 20 to 60 nm and that of the Zn precipitates near or at the grain boundaries increases as well. This microstructure transformation is accompanied at the macroscopic scale by a marked softening of the alloy. The SPD produced by HPT is conducted up to a shear strain of 314. The final Al and Zn grains refine down to the nanoscale with sizes of 370 nm and 170 nm, respectively. As a result of HPT, the Zn–rich (Al) supersaturated solid solution decomposes completely and reaches the equilibrium state corresponding to room temperature and its leads to the material softening. A new microstructure–based model is proposed to describe the softening process occurring during the compression of the supersaturated Al–30wt% Zn alloy. The model successfully describes the above–mentioned phenomena based on a new evolution law expressing the dislocation mean free path as a function of the plastic strain. The softening of the material behavior during HPT process is captured very well by the proposed model that takes into consideration the effects of solid solution hardening and its decomposition, Orowan looping and dislocation density evolution. In particular, it is demonstrated that the softening process that occurs during HPT can be attributed mainly to the decomposition of the supersaturated solid solution and, in a lesser extent, to the evolution of the dislocation mean free path with plastic strain.