H. Ghadbeigi

Damage in dual phase steel DP1000 investigated using digital image correlation and microstructure simulation

Microstructure failure mechanisms and void nucleation in dual-phase (DP) steels during deformation have been studied using a combination of in situ tensile testing in a scanning electron microscope (SEM), digital image correlation (DIC) and finite element (FE) modelling. SEM images acquired during in situ tests were used to follow the evolution of damage within the microstructure of a DP1000 steel. From these images, strain maps were generated using DIC and used as boundary conditions for a FE model to investigate the stress state of martensite and ferrite before the onset of the martensite phase cracking. Based on the simulation results, a maximum principal stress of about 1700 MPa has been estimated for crack initiation in the martensite of the investigated DP1000 steel. The SEM image observations in combination with the FE analyses provide new insights for the development of physically-based damage models for DP-steels.

An optical method for measuring surface roughness of machined carbon fibre-reinforced plastic composites:

Characterization of the damage induced by machining of fibre-reinforced composites is usually performed by measuring surface roughness. Contact-based surface profilometers are the most used equipment in industry; however, it has been found that there are performance limitations which may result when used to measure machined heterogeneous composite surfaces. In this research, surface roughness is characterised using a commercial non-contact optical method, and compared with a conventional stylus profilometer. Unidirectional and multidirectional carbon fibre laminates were edge trimmed and slot milled. The variation in surface roughness was compared using different tool types, fibre orientations and cutting parameters. Surface damage and cutting mechanisms were assessed by using scanning electron microscope images, and the suitability of roughness parameters were also analysed including: Sa, Skewness and Kurtosis. Using the optical system allowed accurate roughness calculation of individual plies on a multidirectional laminate with different fibre orientations. The research has also shown that the optical system, including the use of areal roughness parameters, can increase the accuracy of roughness measurement for machined fibrous composite surfaces and is less sensitive to measurement position than the stylus.

Strain evolution measurement at the microscale of a Dual Phase steel using Digital Image Correlation

Digital Image Correlation (DIC) together with in-situ tensile testing has been used to measure in DP1000 steel the evolution of plastic strains at the microstructure scale. Interrupted tensile tests were performed on specially designed samples and scanning-electron micrographs were taken at regular applied strain intervals. Patterns defined by the microstructural features of the material have been used for the correlation carried out using LAVision software. The full field strain maps produced by DIC show a progressive localisation of deformation into bands at about 45o with respect to the loading direction. Plastic strains as high as 130% have been measured within the ferrite phase.

Deformation-induced microstructural banding in TRIP steels

Microstructure inhomogeneities can strongly influence the mechanical properties of advanced high-strength steels in a detrimental manner. This study of a transformation-induced plasticity (TRIP) steel investigates the effect of pre-existing contiguous grain boundary networks (CGBNs) of hard second-phases and shows how these develop into bands during tensile testing using in situ observations in conjunction with digital image correlation (DIC). The bands form by the lateral contraction of the soft ferrite matrix, which rotates and displaces the CGBNs of second-phases and the individual features within them to become aligned with the loading direction. The more extensive pre-existing CGBNs that were before the deformation already aligned with the loading direction are the most critical microstructural feature for damage initiation and propagation. They induce micro-void formation between the hard second-phases along them, which coalesce and develop into long macroscopic fissures. The hard phases, retained austenite and martensite, were not differentiated as it was found that the individual phases do not play a role in the formation of these bands. It is suggested that minimizing the presence of CGBNs of hard second-phases in the initial microstructure will increase the formability.

Processing Parameter Effects on Residual Stress and Mechanical Properties of Selective Laser Melted Ti6Al4V

Selective laser melting (SLM) process is characterized by large temperature gradients resulting in high levels of residual stress within the additively manufactured metallic structure. SLM-processed Ti6Al4V yields a martensitic microstructure due to the rapid solidification and results in a ductility generally lower than a hot working equivalent. Post-process heat treatments can be applied to SLM components to remove in-built residual stress and improve ductility. Residual stress buildup and the mechanical properties of SLM parts can be controlled by varying the SLM process parameters. This investigation studies the effect of layer thickness on residual stress and mechanical properties of SLM Ti6Al4V parts. This is the first-of-its kind study on the effect of varying power and exposure in conjunction with keeping the energy density constant on residual stress and mechanical properties of SLM Ti6Al4V components. It was found that decreasing power and increasing exposure for the same energy density lowered the residual stress and improved the % elongation of SLM Ti6Al4V parts. Increasing layer thickness resulted in lowering the residual stress at the detriment of mechanical properties. The study is based on detailed experimental analysis along with finite element simulation of the process using ABAQUS to understand the underlying physics of the process.