Search Results (331)

Control of the friction process in stretch-forming conditions, when creating sheet metal, is essential for obtaining components of the quality required. This paper presents an approach to modelling the friction phenomenon at the rounded edges of stamping dies. The aim of the study is to compare the coefficient of friction (CoF) determined from numerous analytical models available in the literature. Experimental studies were conducted using self-developed bending under tension friction testing apparatus. The test material was low-carbon DC01 steel sheeting. Tests were conducted under lubricated conditions, using industrial oil intended for deep drawing operations. The surfaces of countersamples made of 145Cr6 substrate were modified using the ion implantation of Pb (IOPb) and electron beam melting processes. Variation in the CoF in BUT tests was related to continuous deformation-induced changes in surface topography and changes in the mechanical properties of sheet metal due to the work-hardening phenomenon. Under friction testing with a stationary countersample, the largest increase in average roughness (by 19%) was found for the DC01/IOPb friction pair. The friction process caused a significant decrease in kurtosis values. The results show that the difference between the highest and lowest CoF values, determined for the analytical models considered, was approximately 40%. Full article

Single Event Transients (SETs) in clock-distribution networks are a major source of soft errors in synchronous systems. We present a practical framework that assesses SET risk early in the design cycle, before layout and parasitics, using a Vulnerability Function (VF) derived from Verilog fault injection. This framework guides targeted Engineering Change Orders (ECOs), such as clock-net remapping, re-routing, and the selective insertion of SET filters, within a reproducible open-source flow (Yosys, OpenROAD, OpenSTA). A new analytical Soft Error Rate (SER) model for clock trees is also proposed, which decomposes contributions from the root, intermediate levels, and leaves, and is calibrated by SPICE-measured propagation probabilities, area, and particle flux. When coupled with throughput, this model yields a frequency-aware system-level Bit Error Rate (${BER}_{sys}$). The methodology was validated on a First-In First-Out (FIFO) memory, demonstrating a significant vulnerability reduction of approximately 3.35× in READ mode and 2.67× in WRITE mode. Frequency sweeps show monotonic decreases in both clock-tree vulnerability and ${BER}_{sys}$ at higher clock frequencies, a trend attributed to temporal masking and throughput effects. Cross-node SPICE characterization between 65 nm and 28 nm reveals a technology-dependent effect: for the same injected charge, the 28 nm process produces a shorter root-level pulse, which lowers the propagation probability relative to 65 nm and shifts the optimal clock-tree partition. These findings underscore the framework’s key innovations: a technology-independent, early-stage VF for ranking critical clock nets; a clock-tree SER model calibrated by measured propagation probabilities; an ECO loop that converts VF insights into concrete hardening actions; and a fully reproducible open-source implementation. The paper’s scope is architectural and pre-layout, with extensions to broader circuit classes and a full electrical analysis outlined for future work. Full article

Novel structural materials, high-entropy alloys (HEAs), have attracted considerable interest owing to their tunable microstructural designs and adjustable mechanical properties. In the present work, the microstructural evolution and tensile deformation behavior of FeCoNiCrTi_0.2 HEA are comprehensively examined through cold rolling (with 80% thickness reduction) followed by annealing, combined with multiscale characterization techniques (EBSD/TEM) and mechanical tests. The results reveal that the as-rolled microstructure was characterized by the presence of strong Brass, Goss/Brass, and S textures, along with the formation of high-density dislocation walls (DDWs) and dislocation cells (DCs). As the annealing temperature increased, recrystallized grains preferentially nucleated at grain boundaries with higher stress concentrations and dislocation densities. The grain size decreased from 120.33 μm in the as-rolled state to 10.26 μm after annealing at 1000 °C. Low-angle grain boundaries (LAGBs) progressively transformed into high-angle grain boundaries (HAGBs), while the fraction of Σ3 twin boundaries initially decreased and subsequently increased, reaching a maximum of 43.7% after annealing at 1000 °C. At annealing temperatures exceeding 800 °C, deformed grains became equiaxed, with partial retention of primary texture components observed. After annealing at 1000 °C, the yield strength and tensile strength decreased compared to the as-rolled state, while the elongation significantly increased from 17.2% to 69.8% Simultaneously, the yield ratio decreased by 53%, and the strain-hardening capacity was enhanced. Ultimately, a constitutive model integrating the influences of dislocation mean free path and twin boundary obstruction was developed, providing microscopic explanations for the inverse relationship between strength and recrystallization fraction. Full article

High-entropy alloys (HEAs) have shown great promise for applications in extreme service environments due to their exceptional mechanical properties and thermal stability. However, traditional alloy design often struggles to balance multiple properties such as strength and ductility. Constructing heterogeneous microstructures has emerged as an effective strategy to overcome this challenge. With the rapid advancement of additive manufacturing (AM) technologies, their unique ability to fabricate complex, spatially controlled, and non-equilibrium microstructures offers unprecedented opportunities for tailoring heterostructures in HEAs with high precision. This review highlights recent progress in utilizing AM to engineer heterogeneous microstructures in high-performance HEAs. It systematically examines the multiscale heterogeneities induced by the thermal cycling effects inherent to AM techniques such as selective laser melting (SLM) and electron beam melting (EBM). The review further discusses the critical role of these heterostructures in enhancing the synergy between strength and ductility, as well as improving work-hardening behavior. AM enables the design-driven fabrication of tailored microstructures, signaling a shift from traditional “performance-driven” alloy design paradigms toward a new model centered on “microstructural control”. In summary, additive manufacturing provides an ideal platform for constructing heterogeneous HEAs and holds significant promise for advancing high-performance alloy systems. Its integration into alloy design represents both a valuable theoretical framework and a practical pathway for developing next-generation structural materials with multiple performance attributes. 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

The intricate and dynamic cutting behavior observed in titanium alloy turning leads to non-uniform surface and subsurface properties in the workpiece, impacting torsional strength and fatigue life. A transient pose model, founded on the configuration of a turning tool, is developed to elucidate the evolution of the transition surface during transient turning. Through finite element simulation, the plastic deformation, residual stress, and work hardening rate of the machined surface and subsurface of a titanium alloy are quantitatively examined. The torsional strength and fatigue life calculation method is developed based on initial performance parameters derived from the finite element model. This method enables the correlation identification between surface morphology characteristics, surface and subsurface performance parameters, and fatigue properties. Surface morphology, scanning electron microscopy (SEM), and energy-dispersive X-ray spectroscopy (EDS) are employed to quantitatively analyze the surface features and elemental composition of the titanium alloy turning surface, unveiling their influence on torsional fatigue properties. The findings demonstrate the efficacy of the proposed models and methodologies in identifying the torsional fatigue properties and their distribution patterns of titanium alloy turning surfaces. Full article

Welding of maraging steels leads to a microstructural gradient from base material (BM) to weld metal (WM). During post-weld heat treatment (PWHT) the precipitation and reverted austenite (γ_r) reactions will occur defining the mechanical properties. These reactions are affected by the microstructure and local chemical composition of each zone in the “as welded” (AW) condition. This effect has not been clearly described yet nor the evolution of the microstructure. The objective of this work was to analyse the phase transformations at the different zones of the welded joint during the PWHT to explain the microstructure obtained at each zone. Samples of C250 maraging steel were butt-welded by GTAW-P (Gas Tungsten Arc Welding—Pulsed) process without filler material. The AW condition showed an inhomogeneous microhardness profile, associated with a partial precipitation hardening in the subcritical heat affected zone (SC-HAZ) followed by a softening in the intercritical (IC-HAZ) and recrystallized heat affected zone (R-HAZ). A loop-shaped phase was observed between low temperature IC-HAZ and SC-HAZ, associated with γ_r, as well as microsegregation at the weld metal (WM). The microstructural evolution during PWHT (480 °C) was evaluated on samples treated to different times (1–360 min). Microhardness profile along the welded joint was mostly homogeneous after 5 min of PWHT due to precipitation reaction. The microhardness in the WM was lower than in the rest of the joint due to the depletion of Ni, Ti and Mo in the martensite matrix related with the γ_r formation. The isothermal kinetics of precipitation reaction at 480 °C was studied using Differential Scanning Calorimetry (DSC), obtaining a JMAK expression. The average microhardness for each weld zone was proposed for monitoring the precipitation during PWHT, showing a different behaviour for the WM. γ_r in the WM was also quantified and modelled, while in the IC-HAZ tends to increase with PWHT time, affecting the microhardness. Full article

The northern foothills of the Qinling Mountains, a critical ecological barrier and urban–rural transition zone in China, face intensifying rainstorm–flood disasters under climate extremes and rapid urbanization. This study pioneers a remote sensing-driven, dynamically coupled framework by integrating multi-source satellite data, system resilience theory, and spatial modeling to develop a novel “risk identification–resilience assessment–scenario simulation” chain. This framework quantitatively evaluates the nonlinear response mechanisms of town–village systems to flood disasters, emphasizing the synergistic effects of spatial scale, morphology, and functional organization. The proposed framework uniquely integrates three innovative modules: (1) a hybrid risk identification engine combining normalized difference vegetation index (NDVI) temporal anomaly detection and spatiotemporal hotspot analysis; (2) a morpho-functional resilience quantification model featuring a newly developed spatial morphological resilience index (SMRI) that synergizes landscape compactness, land-use diversity, and ecological connectivity through the entropy-weighted analytic hierarchy process (AHP); and (3) a dynamic scenario simulator embedding rainfall projections into a coupled hydrodynamic model. Key advancements over existing methods include the multi-temporal SMRI and the introduction of a nonlinear threshold response function to quantify “safe-fail” adaptation capacities. Scenario simulations reveal a reduction in flood losses under ecological priority strategies, outperforming conventional engineering-based solutions by resilience gain. The proposed zoning strategy prioritizing ecological restoration, infrastructure hardening, and community-based resilience units provides a scalable framework for disaster-adaptive spatial planning, underpinned by remote sensing-driven dynamic risk mapping. This work advances the application of satellite-aided geospatial analytics in balancing ecological security and socioeconomic resilience across complex terrains. 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

Discontinuous dynamic recrystallization is a critical microstructural evolution mechanism during high-temperature deformation, influencing material properties significantly. This study develops a two-dimensional phase-field model to predict steady-state creep rates in the AZ31 magnesium alloy, focusing on DRX during creep. To enhance simulation accuracy, initial microstructures are generated from optical microscopy data, enabling simulations at larger scales with higher representativeness. A novel nucleation methodology is implemented, eliminating the need for nuclei order parameter adaptation, improving computational efficiency. Finite element analysis (FEA) is integrated to capture initial instantaneous deformation. The Kocks–Mecking model is employed to describe the evolution of average dislocation density, accounting for work hardening and dynamic recovery within the initial polycrystalline microstructure. Instead of conventional creep testing, impression creep, a cost-effective alternative, is used for validation. This method provides constant stress and steady penetration velocity, simulating creep conditions effectively. The model accurately predicts recrystallization kinetics and microstructural evolution, exhibiting a strong correlation with experimental results, with an error of approximately 5%. This research provides a robust and efficient approach for predicting creep behavior in high-temperature applications, vital for optimizing material selection and predicting component lifespan in industries. The methodology offers a significant advancement in understanding and predicting DRX-driven creep behavior. Full article

The main dimensional errors in stamped parts are caused by the springback phenomenon. Those errors usually lead to assembly difficulties and/or the malfunction of those parts. The objective of this contribution is to give a comprehensive and detailed view of the sheet metal-forming process of an actual industrial part, with the focus on the setup adjustment of the blank-holder force (BHF), using the springback as the determining factor of the manufacturing quality. The complete cycle of the simulation will be detailed from the experimental determination of the model parameters to the correlation with experimental results of the simulated values. Many studies use simple geometries with limited practical application, failing to provide a quantitative understanding of actual springback in industrial processes. This work aims to offer a realistic reference for springback in a real production part, combining numerical prediction during design using a well-established model and experimental measurements in the factory. The simulation, carried out using LS-DYNA, determines the influence of the BHF in the springback observed in the manufacturing process of a gas cooktop part made from non-stable austenitic 1.4301 steel. The material has been modeled using Barlat’s Yld2000, experimentally determining the strain rate-dependent hardening, yield locus and isotropic–kinematic hardening. To validate the model, an experimental campaign has been developed, testing the part with values of BHF within the range of 50 t to 200 t. The results show that the numerical model is able to represent the influence of the BHF on the springback, demonstrating the relation between them. Full article

The paper analyzes the process of indentation of polymeric materials with a spherical indenter. The loading diagrams P(h) obtained experimentally and by means of finite element method (FEM) are analyzed. The material under study was high-density polyethylene (HDPE) of PE100 grade, taken from a pipeline for gas distribution systems. The aim of the work was to determine the parameters of the computer model, taking into account hardening and creep processes when verifying P(h) diagrams with experimental studies. The influence of variation of the parameters of the calculation formulas on the reliability of the simulation results was analyzed. The results of the calculation of mechanical properties of material on the basis of P(h) diagrams by the Oliver–Pharr method for model and experimental diagrams were compared. The possibility of using computer modeling for the analysis of instrumented indentation processes is demonstrated, since the results revealed the convergence of the elastic modulus of 1078 GPa for FEM and 1083 GPa for the experiment. The conformity of the Oliver–Pharr method for determining the contact depth is also shown, which differed from the model geometry by only 2.3%. Simulation of the indentation process using the Norton model via FEM, as well as determining the parameters of the material deformation function while taking creep into account, makes it possible to describe the process of contact interaction and shows good agreement with experimental data. Full article

In order to reduce the edge waves and defects of the strip in the forming process and obtain better properties of the strip, it is urgent to establish a better flexible cold forming process. In this paper, a finite element model of the production line was established to simulate the forming process, and the effective stress distribution at the corner of the strip was simulated. The effect of cold working hardening was basically consistent with that calculated by the analytical method and tensile test results. A mathematical model of the maximum normal strain along the tangent direction of the strip’s outer edge of each pass was established. With the constraint conditions that the maximum value of the normal strain value of each pass is less than the critical value and the upper and lower limit of the horizontal value of each test factor, and the maximum value of the normal strain of each pass as the goal, the number of cold forming passes, the bending angle of each pass and the working roll diameter of the roll have been determined. The optimized process parameters were used in the simulations. No edge wave at the strip edge and no “Bauschinger effect” in forming before high-frequency induction welding was found. The method proposed in this paper can optimize the key process parameters before the production line is put into operation, minimize the possible buckling of the strip edge during the forming process, and reduce the possible loss caused by design defects. Full article

Conventional rock mechanical testing approaches encounter significant limitations when applied to deeply buried fractured formations, constrained by formidable sampling difficulties, prohibitive costs, and intricate specimen preparation demands. This investigation pioneers an innovative nanoindentation-based multiscale methodology (XRD–ED–SEM integration) that revolutionizes the mechanical characterization of dolostone through drill cuttings analysis, effectively bypassing conventional coring requirements. Our integrated approach combines precision surface polishing with advanced indenter calibration protocols, enabling the continuous stiffness method to achieve unprecedented measurement accuracy in determining micromechanical properties—notably an elastic modulus of 119.47 GPa and hardness of 5.88 GPa—while simultaneously resolving complex indentation size effect mechanisms. The methodology reveals three critical advancements: remarkable 92.7% dolomite homogeneity establishes statistically significant elastic modulus–hardness correlations (R² > 0.89), while residual imprint analysis uncovers a unique brittle–plastic interaction mechanism through predominant rhomboid plasticity (84% occurrence) accompanied by microscale radial cracking (2.1–4.8 μm). Particularly noteworthy is the identification of load-dependent property variations, where surface hardening effects and defect interactions cause 28.7% parameter dispersion below 50 mN loads, progressively stabilizing to <8% variance at higher loading regimes. By developing a micro–macro bridging model that correlates nanoindentation results with triaxial test data within a 12% deviation, this work establishes a groundbreaking protocol for carbonate reservoir evaluation using minimal drill cutting material. The demonstrated methodology not only provides crucial insights for optimizing hydraulic fracture designs and wellbore stability assessments, but it also fundamentally transforms microstructural analysis paradigms in geomechanics through its successful application of nanoindentation technology to complex geological systems. Full article

Aluminum alloy hot stamping technology has quickly become a research hotspot for many scholars due to its ability to solve key challenges such as poor formability, large rebound, and low dimensional accuracy of aluminum alloy sheets at room temperature. This work systematically reviews the progress of Hot-Forming-Quenching (HFQ^®) technology and its optimization processes. The effects of key forming parameters are summarized, including temperature, forming rate, friction, and crimping force on the forming properties of aluminum alloys. Additionally, an ontological model of thermal deformation behavior and damage evolution during hot forming is analyzed. A multifactorial strength prediction model, integrating grain size and reinforcement mechanisms, is highlighted for its ability to accurately predict post-forming yield strength. To address the limitations of HFQ^®, optimization methods for solid solution and aging heat-treatment stages are categorized and evaluated, along with their advantages and disadvantages. Furthermore, the latest advancements in two innovative hot stamping processes (Low-Temperature Hot Form and Quench (LT-HFQ^®) and pre-hardened hot forming (PHF)) are reviewed. LT-HFQ^® improves formability by pre-cooling the sheet while maintaining solution treatment, while PHF utilizes pre-hardened aluminum alloys, enabling brief heating, forming, and quenching to significantly reduce cycle time while ensuring component strength. Finally, by summarizing current technological progress and challenges, future directions for aluminum alloy hot stamping are outlined, including advancements in forming processes, material modeling, and optimization through multidisciplinary collaboration and artificial intelligence to drive further innovation. Full article