Search results

Antiwear mechanism of action of some chemical elements added to lubricant is studied. These elements are transferred from the lubricant into the surface layers of the sliding pair during friction. The mechanism is based on the influence of these elements on the stacking fault energy (SFE) of the materials in the friction pair and leads to changes in the fragmented structure formed in the metals under plastic deformation. Work hardening of the metal surface layers and their predisposition to wear are changed accordingly. Copper and Armco iron, as typical FCC and BCC metals, were chosen for the friction pair materials. Si, Ni, Zn, Co and Ti were used as the additive components to the lubricant. It was found that the addition of different elements to the lubricant leads to alloying by these elements of the surface layers of the metal during the process of friction. It was found that alloying by elements which decreases the SFE of the metal, the average size of surface layer fragments formed during friction increases and the wear rate decreases. The possibility of controlling the wear resistance of metals during friction through the use of appropriate additives is discussed.

The purpose of this paper is to describe several novel techniques for implementing a crystal plasticity (CP) material model in a large deformation, implicit finite element framework.

Starting from the key kinematic assumptions of CP, the presentation develops the necessary CP correction terms to several common objective stress rates and the consistent linearization of the stress update algorithm. Connections to models for slip system hardening are isolated from these processes.

A kinematically consistent implementation is found to require a correction to the stress update to include plastic vorticity developed by slip deformation in polycrystals. A simpler, more direct form for the algorithmic tangent is described. Several numerical examples demonstrate the capabilities and computational efficiency of the formulation.

The implementation assumes isotropic slip system hardening. With simple modifications, the described approach extends readily to anisotropic coupled or uncoupled hardening functions.

The modular formulation and implementation support streamlined development of new models for slip system hardening without modifications of the stress update and algorithmic tangent computations. This implementation is available in the open-source code WARP3D.

In the process of developing the CP formulation, this work realized the need for corrections to the Green-Naghdi and Jaumann objective stress rates to account properly for non-zero plastic vorticity. The paper describes fully the consistent linearization of the stress update algorithm and details a new scheme to implement the model with improved efficiency.

This paper gives a review of the finite element techniques (FE) applied in the area of material processing. The latest trends in metal forming, non‐metal forming and powder metallurgy are briefly discussed. The range of applications of finite elements on the subjects is extremely wide and cannot be presented in a single paper; therefore the aim of the paper is to give FE users only an encyclopaedic view of the different possibilities that exist today in the various fields mentioned above. An appendix included at the end of the paper presents a bibliography on finite element applications in material processing for the last five years, and more than 1100 references are listed.

The surface energy per unit area of material is known to be proportional to the thermal energy at the melting point of the material. The purpose of this paper is to employ the values of the melting points of metals to develop a model that estimates the average surface energies of metals. Average surface energy estimator (ASEE) was developed with the aid of computational intelligence technique on the platform of support vector regression (SVR) using the values of the melting point of the materials as the descriptor.

The development of ASEE which involves 12 data set was conducted by training and testing SVR model using test-set-cross-validation technique. The developed model (ASEE) was used to estimate average surface energies of 3d, 4d, 5d and other selected metals in the periodic table. The average surface energies obtained from ASEE are in good agreement with the experimental values and with the values from other theoretical models.

The accuracy of this developed model coupled with its adoption of descriptor that can be easily obtained makes it a viable alternative in circumventing the difficulty experienced in experimental determination of average surface energies of materials.

Modeling of ASEE has never been reported in the literature. Meanwhile, the use of ASEE will help circumvent the difficulties involved in the experimental determination of average surface energies of materials.

Microstructure-sensitive design (MSD), for optimal performance of engineering components that are sensitive to material anisotropy, has largely been confined to the realm of theory. The purpose of this paper is to insert the MSD framework into a finite element environment in order to arrive at a practical tool for improved selection and design of materials for critical engineering situations.

This study applies the recently developed Hybrid Bishop-Hill (HBH) model to map the yield surface of anisotropic oxygen free electronic copper. Combining this information with the detailed local stresses determined via finite element analysis (FEA), a “configurational yield stress” is determined for the entire component. By varying the material choice/processing conditions and selecting the directionality of anisotropy, an optimal configuration is found.

The paper provides a new FEA-based framework for MSD for yield-limited situations. The approach identified optimal directionality and processing configurations for three engineering situations that are particularly sensitive to material anisotropy.

The microstructure design space for this study is limited to a selection of eight copper materials produced by a range of processing methods, but is generalizable to many materials that exhibit anisotropic behavior.

The introduction of MSD methodology into a finite element environment is a first step toward a comprehensive designer toolkit for exploiting the anisotropy of general materials (such as metals) in a way that is routinely undertaken in the world of fiber-based composite materials. While the gains are not as sizeable (due to the less-extreme anisotropy), in many applications they may be extremely important.

The purpose of this study is to propose extended potentials and investigate the applicability of extended Finnis–Sinclair (FS) potential to Cr with the unit cell structure of body-centered cubic (BCC Cr).

The parameters of each potential are determined by fitting the elastic constants, cohesive energy and mono-vacancy formation energy. Furthermore, the ability of the extended FS potential to describe the crystal defect properties is tested. Finally, the applicability of reproducing the thermal properties of Cr is discussed.

The internal relationship between physical properties and potential function is revealed. The mathematical relationship between physical properties and potential function is derived in detail. The extended FS potential performs well in reproducing physical properties of BCC Cr, such as elastic constants, cohesive energy, surface energy and the properties of vacancy et al. Moreover, good agreement is obtained with the experimental data for predicting the melting point, specific heat and coefficient of thermal expansion.

In this study, new extended potentials are proposed. The extended FS potential is able to reproduce the physical and thermal properties of BCC Cr. Therefore, the new extended potential can be used to describe the crystal defect properties of BCC Cr.

Molecular dynamics is an emerging simulation technique in the field of machining in recent years. Many researchers have tried to simulate different processing methods of various materials with the theory of molecular dynamics (MD), and some preliminary conclusions have been obtained. However, the application of MD simulation is more limited compared with traditional finite element model (FEM) simulation technique due to the complex modeling approach and long computation time. Therefore, more studies on the MD simulations are required to provide a reliable theoretical basis for the nanoscale interpretation of grinding process. This study investigates the crystal structures, dislocations, force, temperature and subsurface damage (SSD) in the grinding of iron-nickel alloy using MD analysis.

In this study the simulation model is established on the basis of the workpiece and single cubic boron nitride (CBN) grit with embedded atom method and Morse potentials describing the forces and energies between different atoms. The effects of grinding parameters on the material microstructure are studied based on the simulation results.

When CBN grit goes through one of the grains, the arrangement of atoms within the grain will be disordered, but other grains will not be easily deformed due to the protection of the grain boundaries. Higher grinding speed and larger cutting depth can cause greater impact of grit on the atoms, and more body-centered cubic (BCC) structures will be destroyed. The dislocations will appear in grain boundaries due to the rearrangement of atoms in grinding. The increase of grinding speed results in the more transformation from BCC to amorphous structures.

This study is aimed to study the grinding of Fe-Ni alloy (maraging steel) with single grit through MD simulation method, and to reveal the microstructure evolution within the affected range of SSD layer in the workpiece. The simulation model of polycrystalline structure of Fe-Ni maraging steel and grinding process of single CBN grit is constructed based on the Voronoi algorithm. The atomic accumulation, transformation of crystal structures, evolution of dislocations as well as the generation of SSD are discussed according to the simulation results.

Plasma spray coating technologies are capable of depositing a wide range of compositions without significantly heating the substrate. The objective is to characterise plasma sprayed metallic coatings on a Fe‐based superalloy.

NiCrAlY, Ni‐20Cr, Ni3Al and Stellite‐6 metallic coatings were deposited on a Fe‐based superalloy (32Ni‐21Cr‐0.3Al‐0.3Ti‐1.5Mn‐1.0Si‐0.1C‐Bal Fe) by the shrouded plasma spray process. The coatings were characterised in relation to coating thickness, porosity, microhardness and microstructure. The high temperature oxidation behaviour of the coatings was investigated in brief. The techniques used in the present investigation include metallography, XRD and SEM/EDAX.

All the coatings exhibited a lamellar structure with distinctive boundaries along with the presence of some porosity and oxide inclusions. The microhardness of the coatings was observed to vary with the distance from the coating‐substrate interface. The St‐6 coating had the maximum microhardness, whereas the lowest hardness was exhibited by the Ni3Al coating. The phases revealed by XRD of the coatings confirmed the formation of solid solutions, whereas EDAX analysis of the as‐sprayed coatings confirmed the presence of basic elements of the coating powders. So far as high temperature oxidation behaviour is concerned, all of the coatings followed the parabolic rate law and resulted in the formation of protective oxide scales on the substrate superalloy.

The plasma spray process provides the possibility of developing coatings of Ni3Al as well as commercial available NiCrAlY, Ni‐20Cr and St‐6 powders on Fe‐based superalloy Superfer 800H

In terms of continuum mechanics a twin is represented by the sudden appearance of a shear eigenstrain state in a distinct region. The corresponding elastic strain energy, the interface energy and the energy dissipated due to the irreversible character of the deformation process are investigated. If the total amount of these energy terms, spent by the twinning process, can be provided by the interaction energy of an external and/or internal stress state with respect to the twin shear eigenstrain, then either a deformation twin band or a twin nucleus may appear. Realistic estimations of the dimensions of deformation twins can be presented. This energetic interpretation of twinning is experimentally demonstrated for intermetallic TiAl.

The purpose of this paper is to analyze theoretically the influence of normal stress on the formability of aluminum alloy sheets in non-linear strain paths.

Four loading modes of non-linear strain paths are investigated in detail to consider the effect of normal stress on formability of aluminum alloy sheets.

Results show that the influence of normal stress in the first stage can be ignored. However, the normal stress in the second stage enhances the formability of aluminum alloy sheets obviously. Besides, the normal stress in the second stage is found to have larger effect on forming limit stress than that in the first stage.

Maybe more experiment data should be obtained to support the theoretical findings.

This current study provides a better understanding of normal stress effect on the formability of aluminum alloy sheets in non-linear strain paths. Since the reacting stage of normal stress play important roles in normal stress effect on the formability of aluminum alloy sheets, the insight obtained in this paper will help to judge the instability of aluminum alloy sheets in complex forming processes with normal stress reacting on the sheet or tube.