Search Results (14)

In a 1987 article of the last author dedicated to the memory of a pioneer of classical plasticity Aris Philips of Yale, the last author outlined three examples of self-organization during plastic deformation in metals: persistent slip bands (PSBs), shear bands (SBs) and Portevin Le Chatelier (PLC) bands. All three have been observed and analyzed experimentally for a long time, but there was no theory to capture their spatial characteristics and evolution in the process of deformation. By introducing the Laplacian of dislocation density and strain in the standard constitutive equations used for these phenomena, corresponding mathematical models and nonlinear partial differential equations (PDEs) for the governing variable were generated, the solution of which provided for the first time estimates for the wavelengths of the ladder structure of PSBs in Cu single crystals, the thickness of stationary SBs in metals and the spacing of traveling PLC bands in Al-Mg alloys. The present article builds upon the 1987 results of the aforementioned three examples of self-organization in plasticity within a unifying internal length gradient (ILG) framework and expands them in 2 major ways by: (i) introducing the effect of stochasticity and (ii) capturing statistical characteristics when PDEs are absent for the description of experimental observations. The discussion focuses on metallic systems, but the modeling approaches can be used for interpreting experimental observations in a variety of materials. Full article

This study aims to explore the effect of microstructural parameters on the notch fatigue damage behavior of the TC21 alloy. Different levels of lamellar microstructures were achieved through distinct aging temperatures of 550 °C, 600 °C, and 650 °C. The findings reveal that increasing aging temperature primarily contributes to the augmentation of α colony (α_c) thickness, grain boundaries α phase (GBα) thickness, and α fine (α_fine) size alongside a reduction in α lath (α_lath) thickness and α_fine content. The notch alters stress distribution and relaxation effects at the root, enhancing notched tensile strength while weakening plasticity. Moreover, the increased thickness of GBα emerges as a critical factor leading to the increase area of intergranular cleavage fracture. It is noteworthy that more thickness α_lath and smaller α_fine facilitate deformation coordination and enhance dislocation accumulation at the interface, leading to a higher propensity for micro-voids and micro-cracks to propagate along the interface. Conversely, at elevated aging temperatures, thinner α_lath and larger α_fine are more susceptible to fracture, resulting in the liberation of dislocations at the interface. The reduction in α_lath thickness is crucial for triggering the initiation of multi-system dislocations at the interface, which promotes the development of persistent slip bands (PSBs) and dislocation nets within α_lath. This phenomenon induces inhomogeneous plastic deformation and localized hardening, fostering the formation of micro-voids and micro-cracks. Full article

Cyclic straining simulations using incompatibility-incorporated crystal plasticity-FEM, which exhibit PSB ladder structure evolutions as detailed in Part I, are coupled with diffusion analyses of produced vacancies. A new vacancy source model is introduced based on the Field Theory of Multiscale Plasticity (FTMP), interpreting the relationship between the incompatibility rate and the flux of dislocation density as edge dipole annihilation processes. Both direct and indirect coupling diffusion analyses, with and without cyclic straining, demonstrate that varying incompatibility rates tend to further promote vacancy diffusion, leading to surface grooving, enhanced extension rates, and eventual transition to cracks. The findings reveal that (i) the evolved PSB ladder structure serves as a site for vacancy formation, (ii) it provides a diffusion path toward the specimen surface, and (iii) it significantly enhances groove extension rates. These factors effectively facilitate the transition from a “groove” to a “crack”, evidenced by the abrupt acceleration of the extension rate, mirroring systematic experimental observations. These achievements validate the FTMP’s capability to simulate complex phenomena and significantly deepen our understanding of slip band–fatigue crack transition mechanisms. Full article

In this study, we successfully reproduced the persistent slip band (PSB) with laddered patterning, showcasing the predictive capability of the framework of Field Theory of Multiscale Plasticity (FTMP) without relying on ad hoc models, intricate mathematical models, or elaborate finite element discretization. The FTMP-incorporated CP-FEM simulation not only reasonably replicates the experimentally observed laddered morphology and PSB but also effectively simulates surface roughening and grooving, independent of vacancy formation and diffusion. These results highlight the significance of laddered morphology and set the stage for further investigations into the effects of vacancy formation, as extended in the subsequent paper. Leveraging incompatibility tensor-based degrees of freedom, the FTMP framework offers exceptional capabilities for natural modeling dislocation substructures typically overlooked in conventional approaches, positioning it as a transformative tool for advancing our understanding of the mechanisms that dictate slip band-fatigue crack transitions. Full article

The aggregation and evolution of dislocations form different configurations, which are the preferred locations for fatigue crack initiation. To analyze the spatial distribution of the same dislocation configuration and the resulting configuration morphologies on different observation planes, several typical hysteresis loops and dislocation configurations in fatigued face-centered cubic single crystals with various orientations were compared. The crystal orientations of these specimens were determined by the electron back-scattering diffraction technique in a Cambridge S360 Scanning Electron Microscope. It is well known that dislocation ladder and wall structures, as well as patch and vein structures, are distributed on their respective observation planes, $(1\overline{2}1)$ and $\left(111\right)$. These correspond to the point defect direction and line defect direction of dislocations, respectively. Therefore, the wall structures on the $(1\overline{2}1)$ and $\left(111\right)$ planes consist of point defects and line defects, which can be defined as point walls and line walls, respectively. Furthermore, the walls on the $(1\overline{2}1)$ plane consist of Persistent Slip Band ladders connected with each other, corresponding to the formation of deformation bands. The evolution of dislocation patterns follows a process from patch to ladder and from vein to wall. The formation of labyrinths and dislocation cells originates from the activation of different secondary slip systems. In one word, it can help us better understand the physical nature of metal fatigue and failure by studying the distribution and evolution of different configurations. Full article

Early in fatigue life, fatigue cracks are often initiated at persistent slip bands (PSBs), which play the main role in surface evolution when the components are subjected to cyclic loading. Therefore, this paper aims to study the behavior of the surface development of medium-carbon steel, specifically 42CrMo4 (SAE 4140). Tests were conducted using tension–compression fatigue testing with stress amplitudes set at 30%, 40%, and 50% of the ultimate tensile strength (UTS); a load ratio of R = −1; and a frequency of f = 10 Hz. The ultimate number of test cycles was 2 × 10⁵. The fatigue test specimens with as-machined surface quality (Ra < 100 nm) were tested on a servo-hydraulic push–pull testing machine, and the tests were interrupted a few times to bring the specimens out for surface measuring with a confocal microscope. The linear roughness values of the arithmetic mean deviation (Ra), maximum height (Rz), maximum profile peak height (Rp), and maximum profile valley depth (Rv) were investigated and further used to determine the roughness evolution during cyclic loading (REC) by analyzing the inclinations of the fitting curves of roughness and number-of-cycles diagrams. REC could then be used to estimate and classify the fatigue lifetime. Full article

Rapid methods for assessing the fatigue properties of materials have been developed, among which the self-heating method stands out as particularly promising. This approach analyzes the thermal signal of the specimen when subjected to cyclic loading. In this research, the self-heating method was utilized for the first time with laser powder bed fusion (LPBF) of NiTi alloys, examining two specific loading conditions: loading ratios of 0.1 and 10. A thorough examination of the material self-heating behavior was conducted. For comparative purposes, conventional fatigue tests were also conducted, alongside interrupted fatigue tests designed to highlight the underlying mechanisms involved in high cycle fatigue and potentially self-heating behavior. The investigation revealed several key mechanisms at play, including intra-grain misorientation, the emergence and growth of persistent slip bands, and the formation of stress-induced martensite. These findings not only deepen our understanding of the fatigue behavior of LPBF NiTi alloys but also highlight the self-heating method potential as a tool for studying material fatigue. Full article

The cyclic plastic deformation of polycrystals leads to the inhomogeneous distribution of the cyclic plastic strain. The cyclic plastic strain is concentrated in thin bands, called persistent slip bands (PSBs). The dislocation structure of these bands generally differs from the matrix structure and is characterized by alternating dislocation-rich and dislocation-poor regions. The mechanisms of the dislocation motion in the PSBs and the formation of the point defects and their migration are quantitatively described. It is shown that, due to localized cyclic plastic straining in the PSBs, persistent slip markings (PSMs) are produced where the PSBs emerge on the surface. They typically consist of a central extrusion accompanied by one or two parallel intrusions. The deep intrusion is equivalent to the crack-like surface defect. The concentration of the cyclic strain in the tip of an intrusion leads to intragranular fatigue crack initiation. The mechanism of the early crack growth in the primary slip plane is proposed and discussed. Numerous PSMs are produced on the surface of the cyclically loaded materials. PSMs contribute to the formation of the surface relief, as well as the relief on the grain boundary. PSMs from one grain impinging the grain boundary are sufficient to create sharp relief on the grain boundary. Void-like defects weaken the grain boundary cohesion and extra material push both grains locally apart. The conditions necessary for the weakening of the grain boundary are enumerated and examples of grain boundary crack initiations are shown. The relevant parameters affecting grain boundary initiation are identified and discussed. The collected experimental evidence and analysis is mostly based on the papers published by the author and his colleagues in the Institute of Physics of Materials in Brno. Full article

In this paper, the minimum temperature and phase shift effects on the thermo–mechanical fatigue (TMF) behavior of Inconel 713LC are investigated. TMF tests were performed under 0° (in-phase-IP) and +180° (out-of-phase-OP) phase shifts between mechanical strain and temperature. Cylindrical specimens were cycled at constant mechanical strain amplitude with a strain ratio of R_ε = −1. Tests were performed with temperature ranges of 300–900 °C and 500–900 °C. The heating and cooling rate was 5 °C/s. Fatigue hardening/softening curves and fatigue life data were assessed. Results show that out-of-phase loading was less damaging than in-phase loading. Scanning electron microscopy (SEM) examination of metallographic sections indicated that the life-reducing damage mechanism was intergranular cavitation under in-phase loading. Transmission electron microscopy (TEM) revealed honeycomb structures for IP loading. The plastic strain localization into persistent slip bands was typical for OP loading. For out-of-phase loading, fatigue damage appeared to be dominant. The increase in the temperature range led to a significant decrease in fatigue life. The reduction of fatigue life was far more pronounced for out-of-phase loading. This can be ascribed to the accelerated crack propagation at high tensile stress under out-of-phase loading as well as the amount of accommodated plastic strain deformation. Based on the SEM scrutiny of metallographic sections and TEM observations of dislocation arrangement, the prevailing damage mechanisms were documented and the lifetime behavior was accordingly discussed. Full article

Fatigue cracks often initiate from the surface extrusion/intrusions formed due to the operation of persistent slip bands (PSBs). Suppression of these surface topographical features by hard surface coatings can significantly extend fatigue lives under lower stress amplitudes (i.e., high cycle fatigue), while cracks initiate early in the coating or in the coating–substrate interface under higher stress amplitudes (i.e., low cycle fatigue), deteriorating the fatigue performance. However, both beneficial and detrimental effects of the coatings appear to be affected by the coating–substrate material combination and coating thickness. A quantitative understanding of the role of these factors in the fatigue performance of materials is still lacking. In this study, crystal plasticity simulations were employed to elucidate the dependence of the coating’s effects on two factors—i.e., the coating thickness and loading amplitudes. The results revealed that the thicker coatings more effectively suppress the operation of the PSBs, but generate higher tensile and shear stresses, normal and parallel to the interfaces, respectively, promoting interfacial delamination. The tensile stresses parallel to the interface within the coating, which favors coating fracture, are not sensitive to the coating thickness. Full article

In this review paper, the evidence and application of thermodynamic self-organization are reviewed for metals typically with single crystals subjected to cyclic loading. The theory of self-organization in thermodynamic processes far from equilibrium is a cutting-edge theme for the development of a new generation of materials. It could be interpreted as the formation of globally coherent patterns, configurations and orderliness through local interactivities by “cascade evolution of dissipative structures”. Non-equilibrium thermodynamics, entropy, and dissipative structures connected to self-organization phenomenon (patterning, orderliness) are briefly discussed. Some example evidences are reviewed in detail to show how thermodynamics self-organization can emerge from a non-equilibrium process; fatigue. Evidences including dislocation density evolution, stored energy, temperature, and acoustic signals can be considered as the signature of self-organization. Most of the attention is given to relate an analogy between persistent slip bands (PSBs) and self-organization in metals with single crystals. Some aspects of the stability of dislocations during fatigue of single crystals are discussed using the formulation of excess entropy generation. Full article

This article presents an experimental investigation on ductile-mode micro-milling of monocrystalline silicon using polycrystalline diamond (PCD) end mills. Experimental results indicate that the irregular fluctuation of cutting force always induces machined surface failure, even in ductile mode. The internal mechanism has not been investigated so far. The multiscale discrete dislocation plasticity framework was used to predict the dislocation structure and strain evolution under the discontinuous cutting process. The results showed that a mass of dislocations can be generated and affected in silicon crystal. The dislocation density, multiplication rate, and microstructure strongly depend on the milling conditions. In particular, transient impulse load can provide a great potential for material strength by forming dislocations entanglement structure. The continuous irregular cutting process can induce persistent slip bands (PSBs) in substrate surface, which would result in stress concentration and inhomogeneous deformation within grains. Full article

The aim of this study is to investigate the fully‐reversed low cycle fatigue properties of Alloy 617 in the air at 950 °C; these tests were conducted at total strain ranges from 0.9% to 1.5% with a constant strain rate of 10−3/s. The result of the fatigue tests showed a decrease in fatigue resistance with an increasing total strain range. The reduction of fatigue resistance was due to the effect of the total strain range and microstructure evolution during high temperature, such as brittle oxides cracking. At all testing conditions, the cyclic softening mechanism was observed as a function of the total strain range in the current high temperature condition. An analysis of low cycle fatigue resistance was performed using the Coffin–Manson relationship and the total strain energy density; it was found that Alloy 617 followed these relationships well. In addition, this study compared well with previous work reported in the literature for a similar testing condition. Post‐fracture analysis on the fracture surfaces of failed specimens revealed a more severe damage cracking at the periphery of specimens due to the increase in the total strain range. The surface connected grain boundary cracks induced by oxidation were obvious at low strain range. Thus, the primary crack propagation occurred in transgranular mode from persistent slip bands. Full article

Interferometric Synthetic Aperture Radar (InSAR) capability to detect slow deformation over terrain areas is limited by temporal decorrelation, geometric decorrelation and atmospheric artefacts. Multitemporal InSAR methods such as Persistent Scatterer (PS-InSAR) and Small Baseline Subset (SBAS) have been developed to deal with various aspects of decorrelation and atmospheric problems affecting InSAR observations. Nevertheless, the applicability of both PS-InSAR and SBAS in mountainous regions is still challenging. Correct phase unwrapping in both methods is hampered due to geometric decorrelation in particular when using C-band SAR data for deformation analysis. In this paper, we build upon the SBAS method implemented in StaMPS software and improved the technique, here called ISBAS, to assess tectonic and volcanic deformation in the center of the Alborz Mountains in Iran using both Envisat and ALOS SAR data. We modify several aspects within the chain of the processing including: filtering prior to phase unwrapping, topographic correction within three-dimensional phase unwrapping, reducing the atmospheric noise with the help of additional GPS data, and removing the ramp caused by ionosphere turbulence and/or orbit errors to better estimate crustal deformation in this tectonically active region. Topographic correction is done within the three-dimensional unwrapping in order to improve the phase unwrapping process, which is in contrast to previous methods in which DEM error is estimated before/after phase unwrapping. Our experiments show that our improved SBAS approach is able to better characterize the tectonic and volcanic deformation in the center of the Alborz region than the classical SBAS. In particular, Damavand volcano shows an average uplift rate of about 3 mm/year in the year 2003–2010. The Mosha fault illustrates left-lateral motion that could be explained with a fault that is locked up to 17–18 km depths and slips with 2–4 mm/year below that depth. Full article