Jay Carroll

An experimental methodology to relate local strain to microstructural texture

This paper introduces an experimental methodology for obtaining high resolution full-field strain measurements in polycrystalline metals. The (sub)grain level resolution of these measurements was indispensable for relating measured strain fields to observed microstructure in the material. Microstructural information was obtained through electron backscatter diffraction and the optical technique of digital image correlation (DIC) was used to acquire full-field deformation measurements. By spatially overlaying both sets of results, the effects of different microstructural features such as orientation, grain boundary character, misorientation between grains, and twin boundaries on material response can be quantitatively studied. To obtain the necessary resolution for such measurements, the images used in DIC had to be captured at high magnifications. This necessity reduces the field of view and constrains the area of interest that can be monitored. To address this issue, results from adjacent measurement areas are combined together to create a data set with high spatial strain resolution over a larger region than can otherwise be observed. The procedure for performing this technique is outlined here, along with benefits, drawbacks, possible modifications, and example applications of the technique to cyclic plasticity and fatigue crack growth.

On the interactions between strain accumulation, microstructure, and fatigue crack behavior

Fatigue crack growth is a complex process that involves interactions between many elements ranging across several length scales. This work provides an in-depth, experimental study of fatigue crack growth and the relationships between four of these elements: strain field, microstructure, crack path, and crack growth rate. Multiple data sets were acquired for fatigue crack growth in a nickel-based superalloy, Hastelloy X. Electron backscatter diffraction was used to acquire microstructural information, scanning electron microscopy was used to identify locations of slip bands and crack path, and optical microscopy was used to measure crack growth rates and to acquire images for multiscale digital image correlation (DIC). Plastic strain accumulation associated with fatigue crack growth was measured at the grain level using DIC. An ex situ technique provided sub-grain level resolution to measure strain variations within individual grains while an in situ technique over the same regions showed the evolution of strain with crack propagation. All of these data sets were spatially aligned to allow direct, full-field comparisons among the variables. This in-depth analysis of fatigue crack behavior elucidates several relationships among the four elements mentioned above. Near the crack tip, lobes of elevated strain propagated with the crack tip plastic zone. Behind the crack tip, in the plastic wake, significant inhomogeneities were observed and related to grain geometry and orientation. Grain structure was shown to affect the crack path and the crack growth rate locally, although the global crack growth rate was relatively constant as predicted by the Paris law for loading with a constant stress intensity factor. Some dependency of crack growth rate on local strain and crack path was also found. The experimental comparisons of grain structure, strain field, and crack growth behavior shown in this work provide insight into the fatigue crack growth process at the sub-grain and multi-grain scale.

Evaluating Deformation-Induced Grain Orientation Change in a Polycrystal During In Situ Tensile Deformation using EBSD

Using an in situ load frame within a scanning electron microscope, a microstructural section on the surface of an annealed tantalum (Ta) polycrystalline specimen was mapped at successive tensile strain intervals, up to ~20% strain, using electron backscatter diffraction. A grain identification and correlation technique was developed for characterizing the evolving microstructure during loading. Presenting the correlated results builds on the reference orientation deviation (ROD) map concept where individual orientation measurements within a grain are compared with a reference orientation associated with that grain. In this case, individual orientation measurements in a deformed grain are measured relative to a reference orientation derived from the undeformed (initial) configuration rather than the current deformed configuration as has been done for previous ROD schemes. Using this technique helps reveal the evolution of crystallographic orientation gradients and development of deformation-induced substructure within grains. Although overall crystallographic texture evolved slowly during deformation, orientation spread within grains developed quickly. In some locations, misorientation relative to the original orientation of a grain exceeded 20° by 15% strain. The largest orientation changes often appeared near grain boundaries suggesting that these regions were preferred locations for the initial development of subgrains.

Room Temperature Deformation Mechanisms of Alumina Particles Observed from In Situ Micro-compression and Atomistic Simulations

Aerosol deposition (AD) is a solid-state deposition technology that has been developed to fabricate ceramic coatings nominally at room temperature. Sub-micron ceramic particles accelerated by pressurized gas impact, deform, and consolidate on substrates under vacuum. Ceramic particle consolidation in AD coatings is highly dependent on particle deformation and bonding; these behaviors are not well understood. In this work, atomistic simulations and in situ micro-compressions in the scanning electron microscope, and the transmission electron microscope (TEM) were utilized to investigate fundamental mechanisms responsible for plastic deformation/fracture of particles under applied compression. Results showed that highly defective micron-sized alumina particles, initially containing numerous dislocations or a grain boundary, exhibited no observable shape change before fracture/fragmentation. Simulations and experimental results indicated that particles containing a grain boundary only accommodate low strain energy per unit volume before crack nucleation and propagation. In contrast, nearly defect-free, sub-micron, single crystal alumina particles exhibited plastic deformation and fracture without fragmentation. Dislocation nucleation/motion, significant plastic deformation, and shape change were observed. Simulation and TEM in situ micro-compression results indicated that nearly defect-free particles accommodate high strain energy per unit volume associated with dislocation plasticity before fracture. The identified deformation mechanisms provide insight into feedstock design for AD.

Comparative Shock Response of Additively Manufactured Versus Conventionally Wrought 304L Stainless Steel.

Gas-gun experiments have probed the compression and release behavior of impact-loaded 304L stainless steel specimens that were machined from additively manufactured (AM) blocks as well as baseline ingot-derived bar stock. The AM technology permits direct fabrication of net- or near-net-shape metal parts. For the present investigation, velocity interferometer (VISAR) diagnostics provided time-resolved measurements of sample response for one-dimensional (i.e., uniaxial strain) shock compression to peak stresses ranging from 0.2 to 7.0 GPa. The acquired wave-profile data have been analyzed to determine the comparative Hugoniot Elastic Limit (HEL), Hugoniot equation of state, spall strength, and high-pressure yield strength of the AM and conventional materials. The possible contributions of various factors, such as composition, porosity, microstructure (e.g., grain size and morphology), residual stress, and/or sample axis orientation relative to the additive manufacturing deposition trajectory, are considered...

Anisotropy and Strain Localization in Dynamic Impact Experiments of Tantalum Single Crystals

Deformation mechanisms in bcc metals, especially in dynamic regimes, show unusual complexity, which complicates their use in high-reliability applications. Here, we employ novel, high-velocity cylinder impact experiments to explore plastic anisotropy in single crystal specimens under high-rate loading. The bcc tantalum single crystals exhibit unusually high deformation localization and strong plastic anisotropy when compared to polycrystalline samples. Several impact orientations - [100], [110], [111] and [

Deformation Behaviors of Sub-micron and Micron Sized Alumina Particles in Compression.

\bar{1}49

A multiscale study of damage in elastomeric syntactic foams

1¯49] - are characterized over a range of impact velocities to examine orientation-dependent mechanical behavior versus strain rate. Moreover, the anisotropy and localized plastic strain seen in the recovered cylinders exhibit strong axial symmetries which differed according to lattice orientation. Two-, three-, and four-fold symmetries are observed. We propose a simple crystallographic argument, based on the Schmid law, to understand the observed symmetries. These tests are the first to explore the role of single-crystal orientation in Taylor impact tests and they clearly demonstrate the importance of crystallography in high strain rate and temperature deformation regimes. These results provide critical data to allow dramatically improved high-rate crystal plasticity models and will spur renewed interest in the role of crystallography to deformation in dynamics regimes.