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Metals
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Deformation, Fracture and Microstructure of Metallic Materials
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Deformation, Fracture and Microstructure of Metallic Materials

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Metal Failure Analysis".

Deadline for manuscript submissions: closed (30 April 2023) | Viewed by 23402

Printed Edition Available!
A printed edition of this Special Issue is available here.

Special Issue Editors

Prof. Dr. Xiao-Wu Li

E-Mail Website
Guest Editor
Department of Materials Physics and Chemistry, School of Materials Science and Engineering, Northeastern University, Shenyang 110819, China
Interests: fatigue; fracture; deformation; strengthening and toughening; microstructure; grain boundary engineering; quantitative fractography; metallic materials; natural biological materials; biomedical materials
Special Issues, Collections and Topics in MDPI journals
Dr. Peng Chen

E-Mail Website
Guest Editor
Department of Materials Physics and Chemistry, School of Materials Science and Engineering, Northeastern University, Shenyang 110819, China
Interests: high-strength steel; phase transformation; mechanical behavior; microstructure characterization
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Metallic materials have been widely and irreplaceably used in modern engineering, attributed to the fact that they possess remarkably complex mechanical properties. In seeking to improve the mechanical properties of metallic materials, an in-depth understanding of deformation and fracture behavior is of particular significance. As is well known, deformation and fracture mechanisms are strongly dependent on the initial microstructure (e.g., grain size, grain boundary character, inclusion, precipitate, phase composition, microstructural and chemical nonuniformity) of materials, which plays a determining role in defining their mechanical properties. In addition, exploring the evolution of microstructure during deformation is also extremely important for understanding of deformation and fracture mechanisms. Therefore, submissions detailing research efforts that look at the microstructure–mechanical property relationships of metallic materials are considered particularly appropriate for this Special Issue. Special attention will be given to the following two aspects (though consideration will not be restricted to submissions on these): (1) rational design of initial microstructures to improve mechanical properties; (2) characterization and analysis of the evolution of deformation microstructures to reveal the deformation and fracture mechanisms.

The aim of this Special Issue is to collect the latest scientific achievements in the microstructure-related deformation and fracture behavior of various metallic materials under monotonical or cyclic loads. All approaches will be considered, including theoretical, numerical, and experimental contributions. Reviews, regular articles, and technical notes are all welcome.

Prof. Dr. Xiao-Wu Li
Dr. Peng Chen
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Metals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • metallic material
  • deformation
  • fracture
  • microstructural design
  • micromechanism
  • mechanical property

Published Papers (12 papers)

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Editorial

Jump to: Research, Review

3 pages, 183 KiB  
Editorial
Deformation, Fracture and Microstructure of Metallic Materials
by Xiaowu Li and Peng Chen
Metals 2023, 13(6), 1015; https://doi.org/10.3390/met13061015 - 25 May 2023
Viewed by 1094
Abstract
Metallic materials are mostly a combination of metallic elements, such as iron, aluminum, magnesium, titanium and manganese, which may also include small amounts of non-metallic elements, such as carbon, nitrogen and oxygen [...] Full article
(This article belongs to the Special Issue Deformation, Fracture and Microstructure of Metallic Materials)

Research

Jump to: Editorial, Review

9 pages, 4429 KiB  
Communication
Revealing the Formation of Recast Layer around the Film Cooling Hole in Superalloys Fabricated Using Electrical Discharge Machining
by Zenan Yang, Lu Liu, Jianbin Wang, Junjie Xu, Wanrong Zhao, Liyuan Zhou, Feng He and Zhijun Wang
Metals 2023, 13(4), 695; https://doi.org/10.3390/met13040695 - 3 Apr 2023
Cited by 2 | Viewed by 1161
Abstract
A film cooling hole is an efficient and reliable cooling method, which is widely used in aeroengine turbine blades to effectively improve the thrust–weight ratio of the engine. Electrical discharge machining is the most common manufacturing process for film cooling holes. Due to [...] Read more.
A film cooling hole is an efficient and reliable cooling method, which is widely used in aeroengine turbine blades to effectively improve the thrust–weight ratio of the engine. Electrical discharge machining is the most common manufacturing process for film cooling holes. Due to the rapid quenching after high-temperature melting, a certain thickness of the recast layer will be formed in the vicinity of the hole wall. The microstructure of the recast layer is considered to be an important factor affecting the performance of single-crystal blades. Generally, the recast layer has been thought of as one of the main reasons for the failure of turbine blades. Accordingly, the formation of the recast layer is an important and interesting issue to be revealed. In this work, the recast layer formed using electrical discharge machining on a single-crystal superalloy is studied with TEM. It is found that the recast layer is in the state of supersaturated solution with a single-crystal structure epitaxially grown from the matrix, and many dislocations were observed therein. Full article
(This article belongs to the Special Issue Deformation, Fracture and Microstructure of Metallic Materials)
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13 pages, 3887 KiB  
Article
Evolution of Poisson’s Ratio in the Tension Process of Low-Carbon Hot-Rolled Steel with Discontinuous Yielding
by Hai Qiu and Tadanobu Inoue
Metals 2023, 13(3), 562; https://doi.org/10.3390/met13030562 - 10 Mar 2023
Cited by 1 | Viewed by 1806
Abstract
Low-carbon hot-rolled steel generally undergoes a deformation process composed of four phases, i.e., elastic deformation, discontinuous yielding, work hardening, and macroscopic plastic-strain localization in a tension test. The evolution of the Poisson’s ratio in terms of the average Poisson’s ratio and the local [...] Read more.
Low-carbon hot-rolled steel generally undergoes a deformation process composed of four phases, i.e., elastic deformation, discontinuous yielding, work hardening, and macroscopic plastic-strain localization in a tension test. The evolution of the Poisson’s ratio in terms of the average Poisson’s ratio and the local Poisson’s ratio in the deformation process from the non-load state to the onset point of specimen necking was investigated. The main results are as follows: (1) the average Poisson’s ratio cannot accurately represent the local Poisson’s ratio in the discontinuous-yielding phase; (2) the Poisson’s ratio varied significantly within a plastic band in the discontinuous-yielding phase, and the maximum Poisson’s ratio was reached within the plastic band; and (3) the strain rate greatly increased the Poisson’s ratio. Full article
(This article belongs to the Special Issue Deformation, Fracture and Microstructure of Metallic Materials)
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16 pages, 8910 KiB  
Article
Fatigue-Damage Initiation at Process Introduced Internal Defects in Electron-Beam-Melted Ti-6Al-4V
by Robert Fleishel, William Ferrell and Stephanie TerMaath
Metals 2023, 13(2), 350; https://doi.org/10.3390/met13020350 - 9 Feb 2023
Cited by 3 | Viewed by 1258
Abstract
Electron Beam Melting (EBM) is a widespread additive manufacturing technology for metallic-part fabrication; however, final products can contain microstructural defects that reduce fatigue performance. While the effects of gas and keyhole pores are well characterized, other defects, including lack of fusion and smooth [...] Read more.
Electron Beam Melting (EBM) is a widespread additive manufacturing technology for metallic-part fabrication; however, final products can contain microstructural defects that reduce fatigue performance. While the effects of gas and keyhole pores are well characterized, other defects, including lack of fusion and smooth facets, warrant additional investigation given their potential to significantly impact fatigue life. Therefore, such defects were intentionally induced into EBM Ti-6Al-4V, a prevalent titanium alloy, to investigate their degradation on stress-controlled fatigue life. The focus offset processing parameter was varied outside of typical manufacturing settings to generate a variety of defect types, and specimens were tested under fatigue loading, followed by surface and microstructure characterization. Fatigue damage primarily initiated at smooth facet sites or sites consisting of un-melted powder due to a lack of fusion, and an increase in both fatigue life and void content with increasing focus offset was noted. This counter-intuitive relationship is attributed to lower focus offsets producing a microstructure more prone to smooth facets, discussed in the literature as being due to lack of fusion or cleavage fracture, and this study indicates that these smooth flaws are most likely a result of lack of fusion. Full article
(This article belongs to the Special Issue Deformation, Fracture and Microstructure of Metallic Materials)
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14 pages, 9194 KiB  
Article
Repair Reliability Analysis of a Special-Shaped Epoxy Steel Sleeve for Low-Strength Tee Pipes
by Jun Cao, Haidong Jia, Weifeng Ma, Ke Wang, Tian Yao, Junjie Ren, Hailiang Nie, Xiaobin Liang and Wei Dang
Metals 2022, 12(12), 2149; https://doi.org/10.3390/met12122149 - 14 Dec 2022
Cited by 1 | Viewed by 1310
Abstract
Ensuring the safe operation of pipe fittings in a natural gas station is critical. The irregular shape of the tee easily leads to uneven mechanical properties in the manufacturing process. The strength of the tee may be lower than the requirements due to [...] Read more.
Ensuring the safe operation of pipe fittings in a natural gas station is critical. The irregular shape of the tee easily leads to uneven mechanical properties in the manufacturing process. The strength of the tee may be lower than the requirements due to its unqualified heat-treatment process. As a result, selecting a reliable way of repairing low-strength tee pipes is a pressing concern. To repair the low-strength tee pipes, a special-shaped epoxy steel sleeve (SSESS) was designed. To optimize the critical design parameters, the SSESS design criteria were established. Following that, the SSESS repair testing was conducted using the optimized design parameters. The SSESS repair reliability was proved using hydraulic burst testing with strain monitoring and simulations of unrepaired and SSESS repaired tees. The result indicated that the SSESS repaired tee’s yielding and burst pressure increased, demonstrating its repair reliability. Furthermore, the SSESS repair revealed the stress and strain concentration decrease law. Full article
(This article belongs to the Special Issue Deformation, Fracture and Microstructure of Metallic Materials)
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Graphical abstract

9 pages, 3511 KiB  
Article
The Effect of Strain Rate on the Deformation Behavior of Fe-30Mn-8Al-1.0C Austenitic Low-Density Steel
by Jiahui Du, Peng Chen, Xianjun Guan, Jiawei Cai, Qian Peng, Chuang Lin and Xiaowu Li
Metals 2022, 12(8), 1374; https://doi.org/10.3390/met12081374 - 18 Aug 2022
Cited by 3 | Viewed by 2180
Abstract
Automotive steels suffer different strain rates during their processing and service. In this study, the effect of strain rates on the tensile properties of fully austenitic Fe-30Mn-8Al-1.0C (wt.%) steel was investigated, and the dominant deformation mechanism was clarified. Conventional and interrupted tension tests [...] Read more.
Automotive steels suffer different strain rates during their processing and service. In this study, the effect of strain rates on the tensile properties of fully austenitic Fe-30Mn-8Al-1.0C (wt.%) steel was investigated, and the dominant deformation mechanism was clarified. Conventional and interrupted tension tests and various microscopic characterization methods were carried out in this study. The results indicate that the yield strength increases with the increasing strain rate in the range of 10−4–10−1 s−1, and a good strength–ductility combination was achieved in the sample deformed at 10−3 s−1. In the process of straining at 10−3 s−1, microbands and deformation twins were observed. Thus, the combination of microband induced plasticity (MBIP) together with twinning induced plasticity (TWIP) leads to a continuous strain hardening behavior, and consequently to superior mechanical properties. However, adiabatic heating that leads to the increase in stacking fault energy (SFE) and inhibits the TWIP effect, as well as thermal softening jointly induces an anomalous decrease in tensile strength at the high strain rate of 10−1 s−1. Full article
(This article belongs to the Special Issue Deformation, Fracture and Microstructure of Metallic Materials)
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15 pages, 48258 KiB  
Article
Quenching Stress of Hot-Rolled Seamless Steel Tubes under Different Cooling Intensities Based on Simulation
by Zhenlei Li, Rui Zhang, Dong Chen, Qian Xie, Jian Kang, Guo Yuan and Guodong Wang
Metals 2022, 12(8), 1363; https://doi.org/10.3390/met12081363 - 16 Aug 2022
Cited by 2 | Viewed by 1461
Abstract
Large residual stress occurs during the quenching process of hot-rolled seamless steel tubes, which results in bending, cracking, and ellipticity exceeding standards and seriously affects the quality of hot-rolled seamless steel tubes. In addition, the stress generation mechanism of hot-rolled seamless steel tubes [...] Read more.
Large residual stress occurs during the quenching process of hot-rolled seamless steel tubes, which results in bending, cracking, and ellipticity exceeding standards and seriously affects the quality of hot-rolled seamless steel tubes. In addition, the stress generation mechanism of hot-rolled seamless steel tubes is different from that of steel plates due to the characteristics of annular section. In this research, the finite element simulation method was used to study the quenching residual stress of seamless steel tubes with different cooling intensities. The variation law of temperature and stress on the steel tube under different cooling intensities were analyzed. The results show that the radial stress was close to 0, and the circumferential and axial stresses were the main factors affecting the quality of the steel tube. With the increase in the cooling time, the magnitude and direction of each stress component of the steel tube changed simultaneously. Finally, a typical stress distribution state of “external compressive stress, internal tensile stress” was presented in the thickness direction of the steel tube. Furthermore, with the increase in the cooling intensity, the residual stress of the steel tube gradually increased and was mainly concentrated on the near wall of the steel tube. Full article
(This article belongs to the Special Issue Deformation, Fracture and Microstructure of Metallic Materials)
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10 pages, 3616 KiB  
Article
Cluster Hardening Effects on Twinning in Mg-Zn-Ca Alloys
by Ruixue Liu, Jie Wang, Leyun Wang, Xiaoqin Zeng and Zhaohui Jin
Metals 2022, 12(4), 693; https://doi.org/10.3390/met12040693 - 18 Apr 2022
Cited by 4 | Viewed by 1939
Abstract
Twinning is a critical deformation mode in Mg alloys. Understanding deformation twinning (DT) is essential to improving mechanical properties of Mg alloys. To address the experimentally observed conspicuous hardening effects in Mg-1.8Zn-0.2Ca alloys, interactions between the {10–12} twin boundaries (TBs) and solute clusters [...] Read more.
Twinning is a critical deformation mode in Mg alloys. Understanding deformation twinning (DT) is essential to improving mechanical properties of Mg alloys. To address the experimentally observed conspicuous hardening effects in Mg-1.8Zn-0.2Ca alloys, interactions between the {10–12} twin boundaries (TBs) and solute clusters in Mg-Zn-Ca alloys were examined via molecular dynamics (MD) simulations. We find that the Zn/Ca-containing clusters show different hindering effects on TBs and an increment in the applied shear stress of 100 MPa is required to accomplish the interaction between the boundary and the cluster with Ca content > 50 at%. The cluster hardening effects on twinning are positively correlated to the Ca content and the size of the clusters in Mg-Zn-Ca alloys. Full article
(This article belongs to the Special Issue Deformation, Fracture and Microstructure of Metallic Materials)
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14 pages, 7477 KiB  
Article
High-Cycle Fatigue Behavior and Fatigue Strength Prediction of Differently Heat-Treated 35CrMo Steels
by Mengqi Yang, Chong Gao, Jianchao Pang, Shouxin Li, Dejiang Hu, Xiaowu Li and Zhefeng Zhang
Metals 2022, 12(4), 688; https://doi.org/10.3390/met12040688 - 17 Apr 2022
Cited by 13 | Viewed by 3297
Abstract
In order to obtain the optimum fatigue performance, 35CrMo steel was processed by different heat treatment procedures. The microstructure, tensile properties, fatigue properties, and fatigue cracking mechanisms were compared and analyzed. The results show that fatigue strength and yield strength slowly increase at [...] Read more.
In order to obtain the optimum fatigue performance, 35CrMo steel was processed by different heat treatment procedures. The microstructure, tensile properties, fatigue properties, and fatigue cracking mechanisms were compared and analyzed. The results show that fatigue strength and yield strength slowly increase at first and then rapidly decrease with the increase of tempering temperature, and both reach the maximum values at a tempering temperature of 200 °C. The yield strength affects the ratio of crack initiation site, fatigue strength coefficient, and fatigue strength exponent to a certain extent. Based on Basquin equation and fatigue crack initiation mechanism, a fatigue strength prediction method for 35CrMo steel was established. Full article
(This article belongs to the Special Issue Deformation, Fracture and Microstructure of Metallic Materials)
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12 pages, 4330 KiB  
Article
Size and Shape Effects on Fatigue Behavior of G20Mn5QT Steel from Axle Box Bodies in High-Speed Trains
by Zhenxian Zhang, Zhongwen Li, Han Wu and Chengqi Sun
Metals 2022, 12(4), 652; https://doi.org/10.3390/met12040652 - 11 Apr 2022
Cited by 6 | Viewed by 1728
Abstract
In this paper, the axial loading fatigue tests are at first conducted on specimens ofG20Mn5QT steel from axle box bodies in high-speed trains. Then, the size and shape effects on fatigue behavior are investigated. It is shown that the specimen size and shape [...] Read more.
In this paper, the axial loading fatigue tests are at first conducted on specimens ofG20Mn5QT steel from axle box bodies in high-speed trains. Then, the size and shape effects on fatigue behavior are investigated. It is shown that the specimen size and shape have an influence on the fatigue performance of G20Mn5QT steel. The fatigue strength of the hourglass specimen is higher than that of the dogbone specimen due to its relatively smaller highly stressed region. Scanning electron microscope observation of the fracture surface and energy dispersive X-ray spectroscopy indicate that the specimen size and shape have no influence on the fatigue crack initiation mechanism. Fatigue cracks initiate from the surface or subsurface of the specimen, and some fracture surfaces present the characteristic of multi-site crack initiation. Most of the fatigue cracks initiate from the pore defects and alumina inclusions in the casting process, in which the pore defects are the main crack origins. The results also indicate that the probabilistic control volume method could be used for correlating the effects of specimen size and shape o the fatigue performance of G20Mn5QT steel for axle box bodies in high-speed trains. Full article
(This article belongs to the Special Issue Deformation, Fracture and Microstructure of Metallic Materials)
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Review

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20 pages, 2322 KiB  
Review
Using Mini-CT Specimens for the Fracture Characterization of Ferritic Steels within the Ductile to Brittle Transition Range: A Review
by Marcos Sánchez, Sergio Cicero, Mark Kirk, Eberhard Altstadt, William Server and Masato Yamamoto
Metals 2023, 13(1), 176; https://doi.org/10.3390/met13010176 - 15 Jan 2023
Cited by 8 | Viewed by 2290
Abstract
The use of mini-CT specimens for the fracture characterization of structural steels is currently a topic of great interest from both scientific and technical points of view, mainly driven by the needs and requirements of the nuclear industry. In fact, the long-term operation [...] Read more.
The use of mini-CT specimens for the fracture characterization of structural steels is currently a topic of great interest from both scientific and technical points of view, mainly driven by the needs and requirements of the nuclear industry. In fact, the long-term operation of nuclear plants requires accurate characterization of the reactor pressure vessel materials and evaluation of the embrittlement caused by neutron irradiation without applying excessive conservatism. However, the amount of material placed inside the surveillance capsules used to characterize the resulting degradation is generally small. Consequently, in order to increase the reliability of fracture toughness measurements and reduce the volume of material needed for the tests, it is necessary to develop innovative characterization techniques, among which the use of mini-CT specimens stands out. In this context, this paper provides a review of the use of mini-CT specimens for the fracture characterization of ferritic steels, with particular emphasis on those used by the nuclear industry. The main results obtained so far, revealing the potential of this technique, together with the main scientific and technical issues will be thoroughly discussed. Recommendations for several key topics for future research are also provided. Full article
(This article belongs to the Special Issue Deformation, Fracture and Microstructure of Metallic Materials)
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19 pages, 10481 KiB  
Review
Twin-Related Grain Boundary Engineering and Its Influence on Mechanical Properties of Face-Centered Cubic Metals: A Review
by Xiaowu Li, Xianjun Guan, Zipeng Jia, Peng Chen, Chengxue Fan and Feng Shi
Metals 2023, 13(1), 155; https://doi.org/10.3390/met13010155 - 12 Jan 2023
Cited by 7 | Viewed by 2274
Abstract
On the basis of reiterating the concept of grain boundary engineering (GBE), the recent progress in the theoretical models and mechanisms of twin-related GBE optimization and its effect on the mechanical properties is systematically summarized in this review. First, several important GBE-quantifying parameters [...] Read more.
On the basis of reiterating the concept of grain boundary engineering (GBE), the recent progress in the theoretical models and mechanisms of twin-related GBE optimization and its effect on the mechanical properties is systematically summarized in this review. First, several important GBE-quantifying parameters are introduced, e.g., the fraction of special grain boundaries (GBs), the distribution of triple-junctions, and the ratio of twin-related domain size to grain size. Subsequently, some theoretical models for the GBE optimization in face-centered cubic (FCC) metals are sketched, with a focus on the model of “twin cluster growth” by summarizing the in-situ and quasi-in-situ observations on the evolution of grain boundary character distribution during the thermal-mechanical process. Finally, some case studies are presented on the applications of twin-related GBE in improving the various mechanical properties of FCC metals, involving room-temperature tensile ductility, high-temperature strength-ductility match, creep resistance, and fatigue properties. It has been well recognized that the mechanical properties of FCC materials could be obviously improved by a GBE treatment, especially at high temperatures or under high cyclic loads; under these circumstances, the materials are prone to intergranular cracking. In short, GBE has tremendous potential for improving the mechanical properties of FCC metallic materials, and it is a feasible method for designing high-performance metallic materials. Full article
(This article belongs to the Special Issue Deformation, Fracture and Microstructure of Metallic Materials)
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