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Finite Element Modeling of Solid State Phenomena in Metals and Alloys

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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Metals and Alloys".

Deadline for manuscript submissions: closed (10 November 2022) | Viewed by 10367

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Prof. Dr. Marc Bernacki

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CEMEF - MINES ParisTech, 06904 Sophia Antipolis, France
Interests: multiscale modeling; numerical methods; numerical metallurgy
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Dear colleagues,

The mechanical and functional properties of metals are strongly related to their microstructures, which are themselves inherited from thermal and mechanical processing. A precise numerical modeling of metallic materials is then a topic of prime importance largely due to the interest in the predictive simulation of materials behavior in order to reduce the difficulty of developing new materials and thanks to the academic interest of this strategy in order to improve our understanding of metallurgical phenomena. In the last several decades, numerous numerical methods have been developed at the mesoscopic scale to model solid-state phenomena taking place during metal forming under the concept of digital materials. A large variety of metallurgical mechanisms can be cited: recrystallization, grain growth, recovery, ductile damage, martensitic transformations, solid/solid diffusive phase transformations, and more globally surface and volume diffusion mechanisms leading also to precipitation, precipitate coalescence, spheroidization, Ostwald ripening, powder densification in additive manufacturing, etc. Finite element approaches remain one of the most powerful numerical strategies, especially when large deformations are considered. This Special Issue will be dedicated to the illustration of recent works in this discipline.

Prof. Marc Bernacki
Guest Editor

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Keywords

finite element modeling
metallic materials
solid-state phenomena
digital materials
mesoscopic scale

Published Papers (6 papers)

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Research

24 pages, 7202 KiB

Open AccessArticle

Investigation of the Influence of Hot Forging Parameters on the Closing Conditions of Internal Metallurgical Defects in Zirconium Alloy Ingots

by Grzegorz Banaszek, Kirill Ozhmegov, Anna Kawalek, Sylwester Sawicki, Medet Magzhanov and Alexandr Arbuz

Materials 2023, 16(4), 1427; https://doi.org/10.3390/ma16041427 - 8 Feb 2023

Cited by 3 | Viewed by 1243

Abstract

In this article, we present research results on the closing conditions of internal metallurgical discontinuities during the hot elongation operation of a Zr-1%Nb alloy ingot using physical and numerical modeling. Research on the influence of thermal and deformation parameters of elongation operations on the rheological behavior of a Zr-1% Nb alloy was conducted using the Gleeble 3800 metallurgical process simulator. Modeling of the influence of thermal–mechanical parameters of hot elongation operations in combinations of rhombic and flat anvils on the closure of metallurgical discontinuities was performed with the help of the FORGE^®NxT 2.1 program. Based on the results of the research, recommendations were made regarding forging elongation technology and the geometry of working tools in order to ensure the closure of metallurgical discontinuities during hot elongation operations of Zr-1% Nb alloy ingots. Full article

(This article belongs to the Special Issue Finite Element Modeling of Solid State Phenomena in Metals and Alloys)

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20 pages, 71565 KiB

Open AccessArticle

Simulation of Continuous Dynamic Recrystallization Using a Level-Set Method

by Victor Grand, Baptiste Flipon, Alexis Gaillac and Marc Bernacki

Materials 2022, 15(23), 8547; https://doi.org/10.3390/ma15238547 - 30 Nov 2022

Cited by 9 | Viewed by 1232

Abstract

Dynamic recrystallization is one of the main phenomena responsible for microstructure evolution during hot forming. Consequently, obtaining a better understanding of dynamic recrystallization mechanisms and being able to predict them is crucial. This paper proposes a full-field numerical framework to predict the evolution of subgrain structures upon grain growth, continuous dynamic recrystallization, and post-dynamic recrystallization. To be able to consider a subgrain structure, two strategies are proposed. One relies on a two-step tessellation algorithm to generate a fully substructured microstructure. The second strategy enables for the simulation of the formation of new subgrains during hot deformation. Using these tools, the grain growth of a fully substructured microstructure is modeled. The influence of microstructure topology, subgrain parameters, and some remaining stored energy due to plastic deformation is discussed. The results highlight that the selective growth of a limited number of subgrains is observed only when mobility is a sigmoidal function of disorientation. The recrystallization kinetics predicted with different criteria for discrimination of recrystallized grains are quantitatively compared. Finally, the ability of the framework to model continuous dynamic and post-dynamic recrystallization is assessed upon a case study representative of the hot extrusion of a zircaloy-4 billet (

T = 650

°C

; \dot{ε} = 1.0 s^{- 1}; ε_{f} = 1.35

). The influence of grain boundary properties and nucleation rules are quantified to evaluate the model sensitivity and suitability. Application of these numerical tools to other thermomechanical conditions and microstructures will be presented in an upcoming article. Full article

(This article belongs to the Special Issue Finite Element Modeling of Solid State Phenomena in Metals and Alloys)

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27 pages, 19103 KiB

Open AccessArticle

Level-Set Modeling of Grain Growth in 316L Stainless Steel under Different Assumptions Regarding Grain Boundary Properties

by Brayan Murgas, Baptiste Flipon, Nathalie Bozzolo and Marc Bernacki

Materials 2022, 15(7), 2434; https://doi.org/10.3390/ma15072434 - 25 Mar 2022

Cited by 2 | Viewed by 1833

Abstract

Two finite element level-set (FE-LS) formulations are compared for the modeling of grain growth of 316L stainless steel in terms of grain size, mean values, and histograms. Two kinds of microstructures are considered: some are generated statistically from EBSD maps, and the others are generated by the immersion of EBSD data in the FE formulation. Grain boundary (GB) mobility is heterogeneously defined as a function of the GB disorientation. On the other hand, GB energy is considered as heterogeneous or anisotropic, which are, respectively, defined as a function of the disorientation and both the GB misorientation and the GB inclination. In terms of mean grain size value and grain size distribution (GSD), both formulations provide similar responses. However, the anisotropic formulation better respects the experimental disorientation distribution function (DDF) and predicts more realistic grain morphologies. It was also found that the heterogeneous GB mobility described with a sigmoidal function only affects the DDF and the morphology of grains. Thus, a slower evolution of twin boundaries (TBs) is perceived. Full article

(This article belongs to the Special Issue Finite Element Modeling of Solid State Phenomena in Metals and Alloys)

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21 pages, 26782 KiB

Open AccessArticle

A 2D Front-Tracking Lagrangian Model for the Modeling of Anisotropic Grain Growth

by Sebastian Florez, Julien Fausty, Karen Alvarado, Brayan Murgas and Marc Bernacki

Materials 2021, 14(15), 4219; https://doi.org/10.3390/ma14154219 - 28 Jul 2021

Cited by 4 | Viewed by 1729

Abstract

Grain growth is a well-known and complex phenomenon occurring during annealing of all polycrystalline materials. Its numerical modeling is a complex task when anisotropy sources such as grain orientation and grain boundary inclination have to be taken into account. This article presents the application of a front-tracking methodology to the context of anisotropic grain boundary motion at the mesoscopic scale. The new formulation of boundary migration can take into account any source of anisotropy both at grain boundaries as well as at multiple junctions (MJs) (intersection point of three or more grain boundaries). Special attention is given to the decomposition of high-order MJs for which an algorithm is proposed based on local grain boundary energy minimisation. Numerical tests are provided using highly heterogeneous configurations, and comparisons with a recently developed Finite-Element Level-Set (FE-LS) approach are given. Finally, the computational performance of the model will be studied comparing the CPU-times obtained with the same model but in an isotropic context. Full article

(This article belongs to the Special Issue Finite Element Modeling of Solid State Phenomena in Metals and Alloys)

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25 pages, 21916 KiB

Open AccessArticle

Study on the High-Speed Milling Performance of High-Volume Fraction SiCp/Al Composites

by Youzheng Cui, Shenrou Gao, Fengjuan Wang, Qingming Hu, Cheng Xu and Fengxia Xu

Materials 2021, 14(15), 4143; https://doi.org/10.3390/ma14154143 - 25 Jul 2021

Cited by 7 | Viewed by 1650

Abstract

Compared with other materials, high-volume fraction aluminum-based silicon carbide composites (hereinafter referred to as SiCp/Al) have many advantages, including high strength, small change in the expansion coefficient due to temperature, high wear resistance, high corrosion resistance, high fatigue resistance, low density, good dimensional stability, and thermal conductivity. SiCp/Al composites have been widely used in aerospace, ordnance, transportation service, precision instruments, and in many other fields. In this study, the ABAQUS/explicit large-scale finite element analysis platform was used to simulate the milling process of SiCp/Al composites. By changing the parameters of the tool angle, milling depth, and milling speed, the influence of these parameters on the cutting force, cutting temperature, cutting stress, and cutting chips was studied. Optimization of the parameters was based on the above change rules to obtain the best processing combination of parameters. Then, the causes of surface machining defects, such as deep pits, shallow pits, and bulges, were simulated and discussed. Finally, the best cutting parameters obtained through simulation analysis was the tool rake angle γ₀ = 5°, tool clearance angle α₀ = 5°, corner radius r = 0.4 mm, milling depth a_p = 50 mm, and milling speed v_c = 300 m/min. The optimal combination of milling parameters provides a theoretical basis for subsequent cutting. Full article

(This article belongs to the Special Issue Finite Element Modeling of Solid State Phenomena in Metals and Alloys)

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37 pages, 24133 KiB

Open AccessArticle

Comparative Study and Limits of Different Level-Set Formulations for the Modeling of Anisotropic Grain Growth

by Brayan Murgas, Sebastian Florez, Nathalie Bozzolo, Julien Fausty and Marc Bernacki

Materials 2021, 14(14), 3883; https://doi.org/10.3390/ma14143883 - 12 Jul 2021

Cited by 9 | Viewed by 1697

Abstract

In this study, four different finite element level-set (FE-LS) formulations are compared for the modeling of grain growth in the context of polycrystalline structures and, moreover, two of them are presented for the first time using anisotropic grain boundary (GB) energy and mobility. Mean values and distributions are compared using the four formulations. First, we present the strong and weak formulations for the different models and the crystallographic parameters used at the mesoscopic scale. Second, some Grim Reaper analytical cases are presented and compared with the simulation results, and the evolutions of individual multiple junctions are followed. Additionally, large-scale simulations are presented. Anisotropic GB energy and mobility are respectively defined as functions of the mis-orientation/inclination and disorientation. The evolution of the disorientation distribution function (DDF) is computed, and its evolution is in accordance with prior works. We found that the formulation called “Anisotropic” is the more physical one, but it could be replaced at the mesoscopic scale by an isotropic formulation for simple microstructures presenting an initial Mackenzie-type DDF. Full article

(This article belongs to the Special Issue Finite Element Modeling of Solid State Phenomena in Metals and Alloys)

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