Search Results (540)

Understanding the limitations of cold-formed aluminum alloys in practice applications is essential, particularly due to the risk of substructural changes and a reduction in strength when exposed to elevated temperatures. In this study, the thermal stability of the ultra-fine-grained (UFG) structure formed by equal channel angular pressing (ECAP) at room temperature and the mechanical properties of the AlSi7MgCu0.5 alloy were investigated. Prior to ECAP, the plasticity of the as-cast alloy was enhanced by a heat treatment consisting of solution annealing, quenching, and artificial aging to achieve an overaged state. Four repetitive passes via ECAP route A resulted in the homogenization of eutectic Si particles within the α-solid solution, the formation of ultra-fine grains and/or subgrains with high dislocation density, and a significant improvement in alloy strength due to strain hardening. The main objective of this work was to assess the microstructural and mechanical stability of the alloy after post-ECAP annealing in the temperature range of 373–573 K. The UFG microstructure was found to be thermally stable up to 523 K, above which notable grain and/or subgrain coarsening occurred as a result of discontinuous recrystallization of the solid solution. Mechanical properties remained stable up to 423 K; above this temperature, a considerable decrease in strength and a simultaneous increase in ductility were observed. Synchrotron radiation X-ray diffraction (XRD) was employed to analyze the phase composition and crystallographic characteristics, while transmission electron microscopy (TEM) was used to investigate substructural evolution. Mechanical properties were evaluated through tensile testing, impact toughness testing, and hardness measurements. Full article

The structural units with different characteristic scales in gradient nanostructured (GS) 316L stainless steel act synergistically to achieve the matching of strength and plasticity, and the intrinsic plasticity of nanoscale and ultrafine grains is fully demonstrated. The macroscopic stress–strain responses of each material unit in the GS surface layer can be measured directly by tension or compression tests on microspecimens. However, the experimental results based on microspecimens do not reflect either the extraordinary strengthening effect caused by non-uniform deformation or the intrinsic plasticity of nanoscale and ultrafine grains. In this paper, a method for constructing depth-dependent constitutive relationships of GS materials was proposed, which combines strain hardening parameter (hardness) with physics-informed neural networks (PINNs). First, the microhardness distribution on the specimen cross-sections was measured after stretching to different strains, and the hardness–strain–force test data were used to construct the depth-dependent PINNs model for the true strain–hardness relationship (PINNs_εH). Hardness–strain–force test data from specimens with uniform coarse grains were used to pre-train the PINNs model for hardness and true stress (PINNs_Hσ), on the basis of which the depth-dependent PINNs_Hσ model for GS materials was constructed by transfer learning. The PINNs_εσ model, which characterizes the depth-dependent constitutive relationships of GS materials, was then constructed using hardness as an intermediate variable. Finally, the accuracy and validation of the PINNs_εσ model were verified by a three-point flexure test and finite element simulation. The modeling method proposed in this study can be used to determine the position-dependent constitutive relationships of heterogeneous materials. Full article

The model explicitly incorporates boundary conditions that account for the complex interplay between sections experiencing varying degrees of reduction. This interaction significantly influences the overall deformation behavior and force loading. The control effect is associated with boundary conditions determined by the unevenness of the compression, which have certain quantitative and qualitative characteristics. These include additional loading, which is less than the main load, which implements the process of plastic deformation, and the ratio of control loads from the entrance and exit of the deformation site. According to this criterion, it follows from experimental data that the controlling effect on the plastic deformation site occurs with a ratio of additional and main loading in the range of 0.2–0.8. The next criterion is the coefficient of support, which determines the area of asymmetry of the force load and is in the range of 2.00–4.155. Furthermore, the criterion of the regulating force ratio at the boundaries of the deformation center forming a longitudinal plastic shear is within the limits of 2.2–2.5 forces and 1.3–1.4 moments of these forces. In this state, stresses and deformations of the plastic medium are able to realize the effects of plastic shaping. The force effect reduces with an increase in the unevenness of the deformation. This is due to a change in height of the longitudinal interaction of the disparate sections of the strip. There is an appearance of a new quality of loading—longitudinal plastic shear along the deformation site. The unbalanced additional force action at the entrance of the deformation source is balanced by the force source of deformation, determined by the appearance of a functional shift in the model of the stress state of the metal. The developed theory, using the generalized method of an argument of functions of a complex variable, allows us to characterize the functional shift in the deformation site using invariant Cauchy–Riemann relations and Laplace differential equations. Furthermore, the model allows for the investigation of material properties such as the yield strength and strain hardening, influencing the size and characteristics of the identified limit state zone. Future research will focus on extending the model to incorporate more complex material behaviors, including viscoelastic effects, and to account for dynamic loading conditions, more accurately reflecting real-world milling processes. The detailed understanding gained from this model offers significant potential for optimizing mill roll designs and processes for enhanced efficiency and reduced energy consumption. Full article

Deep-sea oil and gas pipelines undergo significant plastic strain during reel-lay installation. Additionally, the static strain aging phenomenon that occurs during service can further deteriorate the mechanical properties of the pipelines. This study investigates the plastic deformation mechanism of reel-lay pipeline steel by subjecting the test steel to 5% pre-strain followed by aging treatment at 250 °C for 1 h. The present study systematically correlates the evolution of mechanical properties with microstructural changes through microstructural characterization techniques such as EBSD, TEM, and XRD. The results demonstrate that after pre-straining, the yield strength of the experimental steel increases due to dislocation strengthening and residual stress generation, while its uniform elongation decreases. Although no significant changes in grain size are observed macroscopically, microstructural characterization reveals a substantial increase in dislocation density within the matrix, forming dislocation cells and walls. These substructures lead to a deterioration of the material’s work hardening capacity. Following aging treatment, the tested steel exhibits further increased yield strength and reduced uniform elongation. After aging treatment, although the dislocation density in the matrix slightly decreases and dislocation tangles are somewhat reduced, the Cottrell atmosphere pinning effect leads to a further decline in work hardening capability, ultimately resulting in the deterioration of plasticity in reel-lay pipeline steel. The instantaneous hardening exponent curve shows that the work hardening phenomenon becomes more pronounced in the tested steel after strain aging as the tempering temperature increases. Full article

This study investigates the influence of plastic deformation and temperature on the formation of mechanically induced martensite and the associated changes in hardness in AISI 304 austenitic stainless steel. Cold rolling was performed at three temperatures (20 °C, 0 °C, and −196 °C) and various degrees of deformation (10–70%). Microstructural changes, including the formation of ε and α′ martensite, were characterized using X-ray diffraction (XRD) and electron backscatter diffraction (EBSD). The results confirm that martensitic transformation proceeds via the γ → ε → α′ sequence, with transformation rates and martensite fractions increasing at lower temperatures and higher strains. The stacking fault energy of 25.9 mJ/m² favors this transformation pathway. Transformation rates of α′ martensite fractions significantly increased at lower temperatures and higher strains, 91.8% α′ martensite was observed at just 30% deformation at −196 °C. Hardness measurements revealed a strong correlation with martensite content: strain hardening dominated at lower deformations, while martensite formation became the primary hardening mechanism at higher deformations, especially at cryogenic temperatures. The highest hardness (551 HV) was observed in samples deformed to 70% at −196 °C. The findings provide insights into optimizing the mechanical properties of AISI 304 stainless steel through controlled deformation and temperature conditions. Full article

This study examines the microstructural evolution, mechanical properties, and wear behavior of medium-carbon dual-phase steel (AISI 1040) processed via Multi-Axis Compression (MAC). The DP steel was produced through inter-critical annealing at 745 °C, followed by MAC at 500 °C, resulting in a refined grain microstructure. Optical micrographs confirmed the presence of ferrite and martensite phases after annealing, with significant grain refinement observed following MAC. The average grain size decreased from 66 ± 4 μm to 18 ± 1 μm after nine MAC passes. Mechanical testing revealed substantial improvements in hardness (from 145 ± 9 HV to 298 ± 18 HV) and ultimate tensile strength (from 557 ± 33 MPa to 738 ± 44 MPa), attributed to strain hardening and the Hall–Petch effect. Fractographic analysis revealed a ductile failure mode in the annealed sample, while DP0 and DP9 exhibited a mixed fracture mode. Both DP0 and DP9 samples demonstrated superior wear resistance compared to the annealed sample. However, the DP9 sample exhibited slightly lower wear resistance than DP0, likely due to the fragmentation of martensite induced by high accumulated strain, which could act as crack initiation sites during sliding wear. Furthermore, wear resistance was significantly enhanced due to the combined effects of the DP structure and Severe Plastic Deformation (SPD). These findings highlight the potential of MAC processing for developing high-performance steels suitable for lightweight automotive applications. Full article

Magnesium (Mg) alloys are gaining widespread use in the automotive and construction industries for their potential to enhance performance and lower manufacturing costs, making them ideal for lightweight structural applications. However, despite these advantages, extruding Mg alloys remains technically challenging due to their inherently limited formability and the strong crystallographic textures that form during deformation. This study aimed to comprehensively characterize the ductile fracture behavior of ZM51M Mg alloy round bars under various stress states and to improve the reliability of ductile failure predictions through the application and calibration of multiple uncoupled damage criteria. Tensile and compressive tests were conducted on specimens of varying geometries (dogbone, notched R5, shear, uniaxial compression, and plane strain compression specimens) and dimensions, meticulously cut along the extrusion direction of the round bar. These tests encompassed a wide spectrum of stress–strain responses and fracture characteristics, including uniaxial tension, uniaxial compression, and shear-dominated states. An inverse analysis approach, involving iterative numerical simulation coupled with experimental data, was employed to precisely determine fracture strains from the test results. The plastic deformation behavior was accurately modeled using the combined Swift–Voce hardening law. Subsequently, three prominent uncoupled ductile fracture criteria—Rice–Tracey, DF2014, and DF2016—were calibrated against the experimental data. The DF2016 criterion demonstrated superior predictive accuracy, consistently yielding the most accurate fracture strain predictions and significantly outperforming the Rice–Tracey and DF2014 criteria across the tested stress states. The findings of this work provide significant insights for improving the assessment of formability and fracture prediction in Mg alloys. This research directly contributes to overcoming the challenges associated with their inherent formability limitations and complex deformation textures, thereby facilitating more reliable design and broader adoption of Mg alloys in advanced lightweight structural solutions. Full article

This study presents a comprehensive analytical–numerical approach to determining the elastic–plastic properties of Hybrid Metal Matrix Composites (HMMCs), contrasting with prior research that primarily emphasizes elasticity. Using the finite element method (FEM) and elasticity and plasticity theory, we determined key parameters, including Young’s modulus, Poisson’s ratio, yield strength, and ultimate tensile strength. The method, which also accounts for strain-hardening behavior via the Hollomon model, enables precise simulation of HMMC with randomly distributed reinforcement particles of varying shapes and sizes, offering a realistic representation of the composite microstructure. Verification against the literature confirms the accuracy of the approach in reflecting both elastic and plastic behavior, providing essential insights into the material’s full mechanical response, particularly yield strength and strain-hardening properties, aspects rarely explored in depth in existing studies on HMMCs. Full article

It is essential to develop the optimal hot-working process of the (CoCrNi)₉₄Al₃Ti₃ alloy, a recently developed precipitation-hardened medium-entropy alloy with promising mechanical properties, for its industrial application. In this study, the hot workability of the as-forged (CoCrNi)₉₄Al₃Ti₃ alloy was investigated over a temperature range of 1000 °C to 1150 °C and a strain rate ranging from 0.001 to 1 s⁻¹ using a Gleeble-1500D thermal simulation machine of Dynamic Systems Inc., USA. As a result, the constitutive relationship was established, and the hot deformation activation energy was calculated as 433.2 kJ/mol, suggesting its well-defined plastic flow behavior under low-energy-input conditions. Hot-processing maps were constructed to identify the stable hot-working regions. Microstructure analysis revealed that the hot-forged (CoCrNi)₉₄Al₃Ti₃ alloy exhibited continuous dynamic recrystallization (CDRX) behavior under optimal hot-working conditions. Considering the hot-processing maps and DRX characteristics, the optimal hot-working window of hot-forged (CoCrNi)₉₄Al₃Ti₃ alloy was identified as 1100 °C with a strain rate of 0.1 s⁻¹. This work offers valuable guidance for developing high-efficiency forming processes for (CoCrNi)₉₄Al₃Ti₃ medium-entropy alloy. Full article

Springback represents the deflection of a workpiece after releasing the forming tools or dies, which influences the quality and precision of the final products. It is basically governed by the elastic strain recovery of the material after unloading. Most approaches only implement reverse bending to determine the final shape of the formed product. However, stretch plays significant role whe the blank is held by a blank holder. In this paper, an algorithm is presented to calculate the contributions of both stretch loads and bending moments to elastic deformation during springback for each element, and to combine them mathematically and geometrically to achieve the final shape of the product. Comparing the results of this algorithm for different sheet metal forming processes with experimental measurements demonstrates that this technique successfully predicts a wide range of springback with reasonable accuracy. The advantage of this approach is its accuracy, which is not sensitive to hardening and softening mechanisms, the magnitude of plastic deformation during the forming process, or the size of the object. The application of the proposed formulation is limited to long profiles (plane-strain cases). However, it can be extended to more general applications by adding the effect of torsion and developing equations in 3D space. Due to the explicit nature of the calculations, data-processing time would be reduced significantly compared to the sophisticated algorithms used in commercial software. Full article

The use of aluminum alloys for lightweighting in the automotive industry is becoming widespread. In this study, Johnson–Cook plasticity and damage model parameters were determined to predict the plasticity and damage behavior of 6181A-T4 sheet material using finite element analysis software. Uniaxial tensile tests were performed at four different deformation rates (0.0083–0.333 s⁻¹) using tensile test specimens with four different triaxiality values (0.33, 0.36, 0.45, and 0.74). For a 3 mm thick 6181A-T4 aluminum alloy sheet, Johnson–Cook plasticity parameters were determined by the curve fitting method, and damage parameters were optimized using LS-OPT 7.0 software. Finite element analyses using Johnson–Cook plasticity and damage model parameters were compared with the experimental results, and it was observed that the finite element analyses produced very successful predictions. With the increase in strain rate, the yield strength increased, while the tensile strength showed limited change; uniform elongation, coefficient of hardening, and toughness showed a decreasing trend, and the fracture mode showed a transition from ductile to more brittle behavior. The coefficient of determination (R²) values between the Johnson–Cook model and the experimental data ranged from 0.8601 to 0.9837 depending on the strain-rate value. Full article

In this work, a crystal plasticity (CP)-based continuum modeling approach is employed to investigate the interaction between dislocations and coherent ${\gamma }^{″}$ precipitates in the Inconel 718 (IN718) superalloy. A finite element (FE) model is developed to accurately represent realistic microstructures in IN718, specifically incorporating a disk-shaped precipitate embedded within a matrix phase. A length-scale-dependent CP modeling simulation informed by molecular dynamics (MD) findings is conducted. The results indicate that the three ${\gamma }^{″}$ variants behave differently under uniaxial loading conditions, altering the deformation process in the $\gamma$ phase and leading to significant strain and stress heterogeneities. The presence of dislocation shearing in the ${\gamma }^{″}$ variants reduces the localization of strain and dislocation densities in the adjacent $\gamma$ phase. The strain gradient-governed geometrically necessary dislocation (GND) density plays a dominant role in influencing strain hardening behavior. The length scale effect is further quantified by considering four different precipitate sizes, with the major axis ranging from 12.5 nm to 100 nm. The findings show that smaller precipitate sizes result in stronger strain hardening, and the size of ${\gamma }^{″}$ precipitates significantly alters GND density evolution. Full article

As the severe environmental impacts of plastic pollution demand determined action, the European Union (EU) has included recycling at the core of its policies. Consequently, evolving jurisdiction now aims to achieve a recycling rate of 65% for non-PET plastic bottles by 2040. However, the widespread use of post-consumer high-density polyethylene (rPE-HD) recyclates in household chemical containers is still limited by PP contamination, poor mechanical properties, and low environmental stress cracking resistance (ESCR). Although previous studies have explored the improvement of regranulate properties through additives, few have examined whether reducing the variety of extrusion blow-moulded PE-HD packaging could offer similar benefits. Therefore, two sorted fractions of rPE-HD hollow bodies were processed into regranulates under industrial conditions, including hot washing, extrusion, and deodorisation. Subsequently, both materials underwent comprehensive characterisation regarding their composition and performance. The opaque material, which was sourced from milk bottles in the UK, exhibited greater homogeneity with minor impurities, leading to improved ductility and melt strain hardening at moderate strain rates compared to the mixed material stream, which contained approximately 2.5% PP contamination. However, both rPE-HD recyclates exhibited similar short-term creep behaviour, relatively low strain hardening moduli, and were almost devoid of inorganic particles. Considering the sum of the investigated properties, melt blending with suitable virgin material is likely one of the most effective options to maximise regranulate utilisation in hollow bodies, followed by recycling-oriented packaging design (e.g., for efficient sorting), and the employment of advanced sorting technology. Full article

The Loess Plateau region of China has an anomalous climate and frequent geological disasters. Hipparion laterite in seasonally frozen regions exhibits heightened susceptibility to freeze–thaw (F-T) cycling, which induces progressive structural weakening and significantly elevates the risk of slope instability through mechanisms including pore water phase transitions, aggregate disintegration, and shear strength degradation. This study focuses on the slip zone Hipparion laterite from the Nao panliang landslide in Fugu County, Shaanxi Province. We innovatively integrated F-T cycling tests with ring-shear experiments to establish a hydro-thermal–mechanical coupled multi-scale evaluation framework for assessing F-T damage in the slip zone material. The microstructural evolution of soil architecture and pore characteristics was systematically analyzed through scanning electron microscopy (SEM) tests. Quantitative characterization of mechanical degradation mechanisms was achieved using advanced microstructural parameters including orientation frequency, probabilistic entropy, and fractal dimensions, revealing the intrinsic relationship between pore network anisotropy and macroscopic strength deterioration. The experimental results demonstrate that Hipparion laterite specimens undergo progressive deterioration with increasing F-T cycles and initial moisture content, predominantly exhibiting brittle deformation patterns. The soil exhibited substantial strength degradation, with total reduction rates of 51.54% and 43.67% for peak and residual strengths, respectively. The shear stress–displacement curves transitioned from strain-softening to strain-hardening behavior, indicating plastic deformation-dominated shear damage. Moisture content critically regulates pore microstructure evolution, reducing micropore proportion to 23.57–28.62% while promoting transformation to mesopores and macropores. At 24% moisture content, the areal porosity, probabilistic entropy, and fractal dimension increased by 0.2263, 0.0401, and 0.0589, respectively. Temperature-induced pore water phase transitions significantly amplified mechanical strength variability through cyclic damage accumulation. These findings advance the theoretical understanding of Hipparion laterite’s engineering geological behavior while providing critical insights for slope stability assessment and landslide risk mitigation strategies in loess plateau regions. Full article

The WE43 magnesium alloy has gained attention in orthopedic implants due to its biodegradable properties, particularly for fabricating degradable fasteners. However, research on its hot-forming processes remains limited, primarily focusing on macroscopic finite element mechanical analyses. This study introduces a simplified high-temperature upsetting process and employs a mesoscale crystal plasticity finite element method to model the thermoforming behavior of WE43 fasteners for the first time. Comparative analyses with conventional finite element methods reveal that the crystal plasticity finite element method effectively captures the influence of microstructural evolution on macroscopic deformation. Additionally, temperature effects (25–650 °C) on mechanical performance were systematically evaluated. The results demonstrate that temperatures between 350 °C and 450 °C optimize formability, balancing thermal softening and strain hardening. The crystal plasticity finite element method framework provides enhanced predictive accuracy for micro–macro interactions, offering critical insights for designing biodegradable magnesium alloy implants. Full article