Statistical and stochastic description of microvoid evolution observed in dynamic failure of ductile materials

A brief review is presented of statistical approaches on microdamage evolution. An experimental study of statistical microdamage evolution in two ductile materials under dynamic loading is carried out. The observation indicates that there are large differences in size and distribution of microvoids between these two materials. With this phenomenon in mind, kinetic equations governing the nucleation and growth of microvoids in nonlinear rate-dependent materials are combined with the balance law of void number to establish statistical differential equations that describe the evolution of microvoids' number density. The theoretical solution provides a reasonable explanation of the experimentally observed phenomenon. The effects of stochastic fluctuation which is influenced by the inhomogeneous microscopic structure of materials are subsequently examined (i.e. stochastic growth model). Based on the stochastic differential equation, a Fokker-Planck equation which governs the evolution of the transition probability is derived. The analytical solution for the transition probability is then obtained and the effects of stochastic fluctuation is discussed. The statistical and stochastic analyses may provide effective approaches to reveal the physics of damage evolution and dynamic failure process in ductile materials.

Dynamic failure in ductile porous materials

In this paper, a mathematical model of dynamic fracture in porous ductile materials under intense dynamic general loading is developed. The mathematical model includes the influence of inertial effects and material rate sensitivity, as well as the contribution of surface energy of a void and material work-hardening. In addition, the condition of the void compaction is considered as well. The threshold stresses for the void growth and compaction are obtained. A simple criterion for ductile fracture which is associated with material distention and plastic deformation is adopted. As an application of the theoretical model, the processes of two-dimensional spallation in LY12 aluminum alloy are successfully simulated by means of two-dimensional finite-difference Lagrangian code.

Material response and failure mechanism of unidirectional metal matrix composites under impulsive shear loading

The material response and failure mechanism of unidirectional metal matrix composite under impulsive shear loading are investigated in this paper. Both experimental and analytical studies were performed. The shear strength of unidirectional C-f/A356.0 composite and A356.0 aluminum alloy at high strain rate were measured with a modified split Hopkinson torsional bar technique. The results indicated that the carbon fibers did not improve the shear strength of aluminum matrix if the fiber orientation aligned with the shear loading axis. The microscopic inspection of the fractured surface showed a multi-scale zigzag feature which implied a complicated shear failure mechanism in the composite. In addition to testing, the micromechanical stress field in the composite was analyzed by the generalized Eshelby equivalent method (GEEM). The influence of cracking in matrix on the micromechanical stress field was investigated as well. The results showed that the stress distribution in the composite is quite nonhomogeneous and very high shear stress concentrations are found in some regions in the matrix. The high shear stress concentration in the matrix induces tensile cracking at 45 degrees to the shear direction. This in turn aggravates the stress concentration at the fiber/matrix interface and finally leads to a catastrophic failure in the composite. From the correlation between the analysis and experimental results, the shear failure mechanism of unidirectional C-f/A356.0 composite can be elucidated qualitatively.

Influence of 2 secondary effects on shear failure of cantilever with attached mass block under impulsive loading

The influence of two secondary effects, rotatory inertia and presence of a crack, on the dynamic plastic shear failure of a cantilever with an attached mass block at its tip subjected to impulsive loading is investigated. It is illustrated that the consideration of the rotatory inertia of the cantilever and the presence of a crack at the upper root of the beam both increase the initial kinetic energy of the block required to cause shear failure at the interface between the beam tip and the tip mass, where the initial velocity has discontinuity Therefore, the influence of these two secondary effects on the dynamic shear failure is not negligible.

Investigation Of Mode Ii Crack Growth Following A Very High Speed Impact

A recoverable plate impact testing technology has been developed for studying fracture mechanisms of mode II crack. With this technology, a single duration stress pulse with submicrosecond duration and high loading rates, up to 10(8) MPam(1/2)s(-1), can be produced. Dynamic failure tests of Hard-C 60# steel were carried out under asymmetrical impacting conditions with short stress-pulse loading. Experimental results show that the nucleation and growth of several microcracks ahead of the crack tip, and the interactions between them, induce unsteady crack growth. Failure mode transitions during crack growth, both from mode I crack to mode II and from brittle to ductile fracture, were observed. Based on experimental observations, a discontinuous crack growth model was established. Analysis of the crack growth mechanisms using our model shows that the shear crack extension is unsteady when the extending speed is between the Rayleigh wave speed c(R) and the shear wave speed c(S). However, when the crack advancing speed is beyond c(S), the crack grows at a steady intersonic speed approaching root 2c(S). It also shows that the transient mechanisms, such as nucleation, growth, interaction and coalescence among microcracks, make the main crack speed jump from subsonic to intersonic and the steady growth of all the subcracks causes the main crack to grow at a stable intersonic speed.

On laser-induced reverse plugging effect

A new kind of failure induced by long pulsed laser, named as reverse plugging effect (RPE), was experimentally observed in thin foil of brass. The whole failure process can be divided into three stages, namely thermal reverse bulging, shear deformation localization and reverse perforation. In this paper, a description of experimental and theoretical study on this newly discovered phenomenon is presented in detail.

Finite-Element Simulations of Earthquakes

This thesis discusses simulations of earthquake ground motions using prescribed ruptures and dynamic failure. Introducing sliding degrees of freedom led to an innovative technique for numerical modeling of earthquake sources. This technique allows efficient implementation of both prescribed ruptures and dynamic failure on an arbitrarily oriented fault surface. Off the fault surface the solution of the three-dimensional, dynamic elasticity equation uses well known finite-element techniques. We employ parallel processing to efficiently compute the ground motions in domains containing millions of degrees of freedom.

Using prescribed ruptures we study the sensitivity of long-period near-source ground motions to five earthquake source parameters for hypothetical events on a strike-slip fault (M_w 7.0 to 7.1) and a thrust fault (M_w 6.6 to 7.0). The directivity of the ruptures creates large displacement and velocity pulses in the ground motions in the forward direction. We found a good match between the severity of the shaking and the shape of the near-source factor from the 1997 Uniform Building Code for strike-slip faults and thrust faults with surface rupture. However, for blind thrust faults the peak displacement and velocities occur up-dip from the region with the peak near-source factor. We assert that a simple modification to the formulation of the near-source factor improves the match between the severity of the ground motion and the shape of the near-source factor.

For simulations with dynamic failure on a strike-slip fault or a thrust fault, we examine what constraints must be imposed on the coefficient of friction to produce realistic ruptures under the application of reasonable shear and normal stress distributions with depth. We found that variation of the coefficient of friction with the shear modulus and the depth produces realistic rupture behavior in both homogeneous and layered half-spaces. Furthermore, we observed a dependence of the rupture speed on the direction of propagation and fluctuations in the rupture speed and slip rate as the rupture encountered changes in the stress field. Including such behavior in prescribed ruptures would yield more realistic ground motions.

Deformation and fracture of impulsively loaded sandwich panels

Light metal sandwich panel structures with cellular cores have attracted interest for multifunctional applications which exploit their high bend strength and impact energy absorption. This concept has been explored here using a model 6061-T6 aluminum alloy system fabricated by friction stir weld joining extruded sandwich panels with a triangular corrugated core. Micro-hardness and miniature tensile coupon testing revealed that friction stir welding reduced the strength and ductility in the welds and a narrow heat affected zone on either side of the weld by approximately 30%. Square, edge clamped sandwich panels and solid plates of equal mass per unit area were subjected to localized impulsive loading by the impact of explosively accelerated, water saturated, sand shells. The hydrodynamic load and impulse applied by the sand were gradually increased by reducing the stand-off distance between the test charge and panel surfaces. The sandwich panels suffered global bending and stretching, and localized core crushing. As the pressure applied by the sand increased, face sheet fracture by a combination of tensile stretching and shear-off occurred first at the two clamped edges of the panels that were parallel with the corrugation and weld direction. The plane of these fractures always lay within the heat affected zone of the longitudinal welds. For the most intensively loaded panels additional cracks occurred at the other clamped boundaries and in the center of the panel. To investigate the dynamic deformation and fracture processes, a particle-based method has been used to simulate the impulsive loading of the panels. This has been combined with a finite element analysis utilizing a modified Johnson-Cook constitutive relation and a Cockcroft-Latham fracture criterion that accounted for local variation in material properties. The fully coupled simulation approach enabled the relationships between the soil-explosive test charge design, panel geometry, spatially varying material properties and the panel's deformation and dynamic failure responses to be explored. This comprehensive study reveals the existence of a strong instability in the loading that results from changes in sand particle reflection during dynamic evolution of the panel's surface topology. Significant fluid-structure interaction effects are also discovered at the sample sides and corners due to changes of the sand reflection angle by the edge clamping system. © 2012 Elsevier Ltd. All rights reserved.

Application of Numerical Methods to Study Arrangement and Fracture of Lithium-Ion Microstructure

The focus of this work is to develop and employ numerical methods that provide characterization of granular microstructures, dynamic fragmentation of brittle materials, and dynamic fracture of three-dimensional bodies.

We first propose the fabric tensor formalism to describe the structure and evolution of lithium-ion electrode microstructure during the calendaring process. Fabric tensors are directional measures of particulate assemblies based on inter-particle connectivity, relating to the structural and transport properties of the electrode. Applying this technique to X-ray computed tomography of cathode microstructure, we show that fabric tensors capture the evolution of the inter-particle contact distribution and are therefore good measures for the internal state of and electronic transport within the electrode.

We then shift focus to the development and analysis of fracture models within finite element simulations. A difficult problem to characterize in the realm of fracture modeling is that of fragmentation, wherein brittle materials subjected to a uniform tensile loading break apart into a large number of smaller pieces. We explore the effect of numerical precision in the results of dynamic fragmentation simulations using the cohesive element approach on a one-dimensional domain. By introducing random and non-random field variations, we discern that round-off error plays a significant role in establishing a mesh-convergent solution for uniform fragmentation problems. Further, by using differing magnitudes of randomized material properties and mesh discretizations, we find that employing randomness can improve convergence behavior and provide a computational savings.

The Thick Level-Set model is implemented to describe brittle media undergoing dynamic fragmentation as an alternative to the cohesive element approach. This non-local damage model features a level-set function that defines the extent and severity of degradation and uses a length scale to limit the damage gradient. In terms of energy dissipated by fracture and mean fragment size, we find that the proposed model reproduces the rate-dependent observations of analytical approaches, cohesive element simulations, and experimental studies.

Lastly, the Thick Level-Set model is implemented in three dimensions to describe the dynamic failure of brittle media, such as the active material particles in the battery cathode during manufacturing. The proposed model matches expected behavior from physical experiments, analytical approaches, and numerical models, and mesh convergence is established. We find that the use of an asymmetrical damage model to represent tensile damage is important to producing the expected results for brittle fracture problems.

The impact of this work is that designers of lithium-ion battery components can employ the numerical methods presented herein to analyze the evolving electrode microstructure during manufacturing, operational, and extraordinary loadings. This allows for enhanced designs and manufacturing methods that advance the state of battery technology. Further, these numerical tools have applicability in a broad range of fields, from geotechnical analysis to ice-sheet modeling to armor design to hydraulic fracturing.

A finite element analysis of dynamic fracture initiation by ductile failure mechanisms in a 4340 steel

In some recent dropweight impact experiments [5] with pre-notched bend specimens of 4340 steel, it was observed that considerable crack tunneling occurred in the interior of the specimen prior to gross fracture initiation on the free surfaces. The final failure of the side ligaments happened because of shear lip formation. The tunneled region is characterized by a flat, fibrous fracture surface. In this paper, the experiments of [5] (corresponding to 5 m/s impact speed) are analyzed using a plane strain, dynamic finite element procedure. The Gurson constitutive model that accounts for the ductile failure mechanisms of micro-void nucleation, growth and coalescence is employed. The time at which incipient failure was observed near the notch tip in this computation, and the value of the dynamic J-integral, J d, at this time, compare reasonably well with experiments. This investigation shows that J-controlled stress and deformation fields are established near the notch tip whenever J d , increases with time. Also, it is found that the evolution of micro-mechanical quantities near the notch root can be correlated with the time variation of J d .The strain rate and the adiabatic temperature rise experienced at the notch root are examined. Finally, spatial variations of stresses and deformations are analyzed in detail.

Prediction of structural dynamic plastic shear failure by Johnson's damage number

It is proved that Johnson's damage number is the sole similarity parameter for dynamic plastic shear failure of structures loaded impulsively, therefore, dynamic plastic shear failure can be understood when damage number reaches a critical value. It is suggested that the damage number be generally used to predict the dynamic plastic shear failure of structures under various kinds of dynamic loads (impulsive loading, rectangular pressure pulse, exponential pressure pulse, etc.,). One of the advantages for using the damage number to predict such kind of failure is that it is conveniently used for dissimilar material modeling.

Dynamic damage and failure in viscoplastic materials

In this paper, a dynamic damage model in ductile solids under the application of a dynamic mean tensile stress is developed. The proposed model considers void nucleation and growth as parts of the damage process under intense dynamic loading (strain rates epsilon greater than or equal to 10(3) s(-1)). The evolution equation of the ductile void has the closed form, in which work-hardening behavior, rate-dependent contribution and inertial effects are taken into account. Meanwhile, a plate impact test is performed for simulating the dynamic fracture process in LY12 aluminum alloy. The damage model is incorporated in a hydrodynamic computer code, to simulate the first few stress reverberations in the target as it spalls and postimpact porosity in the specimen. Fair agreement between computed and experimental results is obtained. Numerical analysis shows that the influence of inertial resistance on the initial void growth in the case of high loading rate can not be neglected. It is also indicated that the dynamic growth of voids is highly sensitive to the strain rates.