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Metals
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Modelling and Simulation of Microstructure Evolution in Manufacturing Processes
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Modelling and Simulation of Microstructure Evolution in Manufacturing Processes

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Computation and Simulation on Metals".

Deadline for manuscript submissions: closed (31 August 2021) | Viewed by 9200

Special Issue Editor

Prof. Dr. Hamid Assadi

E-Mail Website
Guest Editor
Brunel University London, UK
Interests: modelling and simulation; microstructure; mechanical properties; solidification; cold spray

Special Issue Information

Dear Colleagues,

Properties of metallic materials depend not only on their chemical composition, but also to a large extent on their microstructure, which evolves during various steps of manufacturing, e.g., from casting, extrusion, or hot rolling to heat treatment, cold forming, or welding. Modelling and simulation can enhance our understanding of microstructure evolution and hence provide a complement to experimentation, to predict, control and design microstructures for superior properties and optimum performance of metallic components.

This Special Issue is to serve as a source of information on recent advances in the area of microstructure modelling for scientists and engineers with an interest in manufacturing with metals. The aim is to provide a variety of examples of research and development activities in this field, where an analytical or numerical method is used to model microstructure formation in metallic materials during a manufacturing process.

Examples of the manufacturing processes include casting, additive manufacturing, heat treatment, welding, forming, and coating. Contributions that combine experiments with any modelling technique, numerical or analytical, to predict, understand or control microstructural features such as grain size, phase fraction, or dislocation density are particularly welcome.

Prof. Dr. Hamid Assadi
Guest Editor

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

  • modelling
  • simulation
  • finite element analysis
  • computational fluid dynamics
  • thermodynamic modelling
  • kinetic modelling
  • phase field method
  • mean-field method
  • cellular automata
  • microstructure
  • grain structure
  • solidification
  • forming
  • coating
  • welding
  • additive manufacturing

Published Papers (4 papers)

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Research

20 pages, 3965 KiB  
Article
Modelling of Hot Flow Stress of Duplex Steel in Dependence of Microstructure Using the Rule of Mixture
by Angela Quadfasel, Jürgen A. Nietsch, Marco Teller and Gerhard Hirt
Metals 2021, 11(8), 1285; https://doi.org/10.3390/met11081285 - 15 Aug 2021
Cited by 2 | Viewed by 2118
Abstract
The ferrite fraction and phase distribution of duplex steels depend strongly on the temperature evolution during hot deformation and are correlated to different mechanical behaviors during hot deformation as well as cold deformation. Therefore, the control of microstructure evolution during hot forming is [...] Read more.
The ferrite fraction and phase distribution of duplex steels depend strongly on the temperature evolution during hot deformation and are correlated to different mechanical behaviors during hot deformation as well as cold deformation. Therefore, the control of microstructure evolution during hot forming is relevant for target-oriented material design. In flow stress modelling for hot forming, the influence of microstructure beyond the ferrite fraction is often neglected. In the present work, a new method is demonstrated to also consider the influence of grain size in flow stress modelling. For this purpose, different initial microstructures with different ferrite fractions and phase distribution were tested in compression tests at 1100 °C and 0.1 s−1. The microstructure was analyzed before and after forming and it was observed that the differences in ferrite fractions vanished during the compression tests. Those microstructure data were used in a model including a rule of mixture and Hall–Petch relationship to extract the single-phase flow curves of ferrite and austenite. Based on the flow stress of the single phases, in combination with ferrite fraction and individual grain size, the flow curves of the different material conditions were calculated and the concurrent influence of ferrite fraction and phase distance on the mechanical behavior was discussed. Full article
(This article belongs to the Special Issue Modelling and Simulation of Microstructure Evolution in Manufacturing Processes)
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18 pages, 16254 KiB  
Article
Unified Modelling of Flow Stress and Microstructural Evolution of 300M Steel under Isothermal Tension
by Rongchuang Chen, Shiyang Zhang, Min Wang, Xianlong Liu and Fei Feng
Metals 2021, 11(7), 1086; https://doi.org/10.3390/met11071086 - 07 Jul 2021
Cited by 3 | Viewed by 1741
Abstract
Constitutive models that reflect the microstructure evolution is of great significance to accurately predict the forming process of forging. Through thermal tension of 300M steel under various temperatures (950~1150 °C) and strain rates (0.01~10 s−1), the material flow and microstructure evolutions [...] Read more.
Constitutive models that reflect the microstructure evolution is of great significance to accurately predict the forming process of forging. Through thermal tension of 300M steel under various temperatures (950~1150 °C) and strain rates (0.01~10 s−1), the material flow and microstructure evolutions were investigated. In order to describe both the exponential hardening phenomenon at a higher temperature, and the softening phenomenon due to recrystallization at a lower temperature, a constitutive model considering microstructure evolution was proposed based on the Kocks–Mecking model. It was found that considering the stress-strain curve to be exponential in the work-hardening stage could improve the constitutive model prediction precision. The average error was 2.43% (3.59 MPa), showing that the proposed model was more precise than the modified Arrhenius model and the Kocks–Mecking model. The models to describe recrystallization kinetics and average grain size were also constructed. This work enabled the Kocks–Mecking model to predict stress-strain curves with a higher accuracy, and broadened the applicable range of the Kocks–Mecking model. Full article
(This article belongs to the Special Issue Modelling and Simulation of Microstructure Evolution in Manufacturing Processes)
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15 pages, 3615 KiB  
Article
Modelling of Microstructure Evolution during Laser Processing of Intermetallic Containing Ni-Al Alloys
by Mohammad Amin Jabbareh and Hamid Assadi
Metals 2021, 11(7), 1051; https://doi.org/10.3390/met11071051 - 30 Jun 2021
Cited by 5 | Viewed by 2040
Abstract
There is a growing interest in laser melting processes, e.g., for metal additive manufacturing. Modelling and numerical simulation can help to understand and control microstructure evolution in these processes. However, standard methods of microstructure simulation are generally not suited to model the kinetic [...] Read more.
There is a growing interest in laser melting processes, e.g., for metal additive manufacturing. Modelling and numerical simulation can help to understand and control microstructure evolution in these processes. However, standard methods of microstructure simulation are generally not suited to model the kinetic effects associated with rapid solidification in laser processing, especially for material systems that contain intermetallic phases. In this paper, we present and employ a tailored phase-field model to demonstrate unique features of microstructure evolution in such systems. Initially, the problem of anomalous partitioning during rapid solidification of intermetallics is revisited using the tailored phase-field model, and the model predictions are assessed against the existing experimental data for the B2 phase in the Ni-Al binary system. The model is subsequently combined with a Potts model of grain growth to simulate laser processing of polycrystalline alloys containing intermetallic phases. Examples of simulations are presented for laser processing of a nickel-rich Ni-Al alloy, to demonstrate the application of the method in studying the effect of processing conditions on various microstructural features, such as distribution of intermetallic phases in the melt pool and the heat-affected zone. The computational framework used in this study is envisaged to provide additional insight into the evolution of microstructure in laser processing of industrially relevant materials, e.g., in laser welding or additive manufacturing of Ni-based superalloys. Full article
(This article belongs to the Special Issue Modelling and Simulation of Microstructure Evolution in Manufacturing Processes)
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16 pages, 4434 KiB  
Article
Numerical Study and Experimental Validation of Deformation of <111> FCC CuAl Single Crystal Obtained by Additive Manufacturing
by Anton Y. Nikonov, Andrey I. Dmitriev, Dmitry V. Lychagin, Lilia L. Lychagina, Artem A. Bibko and Olga S. Novitskaya
Metals 2021, 11(4), 582; https://doi.org/10.3390/met11040582 - 02 Apr 2021
Cited by 9 | Viewed by 2544
Abstract
The importance of taking into account directional solidification of grains formed during 3D printing is determined by a substantial influence of their crystallographic orientation on the mechanical properties of a loaded material. This issue is studied in the present study using molecular dynamics [...] Read more.
The importance of taking into account directional solidification of grains formed during 3D printing is determined by a substantial influence of their crystallographic orientation on the mechanical properties of a loaded material. This issue is studied in the present study using molecular dynamics simulations. The compression of an FCC single crystal of aluminum bronze was performed along the <111> axis. A Ni single crystal, which is characterized by higher stacking fault energy (SFE) than aluminum bronze, was also considered. It was found that the first dislocations started to move earlier in the material with lower SFE, in which the slip of two Shockley partials was observed. In the case of the material with higher SFE, the slip of a full dislocation occurred via successive splitting of its segments into partial dislocations. Regardless of the SFE value, the deformation was primarily occurred by means of the formation of dislocation complexes involved stair-rod dislocations and partial dislocations on adjacent slip planes. Hardening and softening segments of the calculated stress–strain curve were shown to correspond to the periods of hindering of dislocations at dislocation pileups and dislocation movement between them. The simulation results well agree with the experimental findings. Full article
(This article belongs to the Special Issue Modelling and Simulation of Microstructure Evolution in Manufacturing Processes)
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