John J. Lewandowski

Intrinsic plasticity or brittleness of metallic glasses

The intrinsic plasticity or brittleness of crystalline metals correlates with the ratio of the elastic shear modulus μ to the bulk modulus B; when the ratio μ/B exceeds a critical value, the metal is brittle. Sufficient data on elastic moduli and toughness are now available to permit an assessment for metallic glasses. We find a similar correlation, with the critical value of μ/B for metallic glasses (0.41–0.43) more sharply defined than for crystalline metals. This critical value applies also for annealing-induced embrittlement of metallic glasses. The clear correlation between mechanical behaviour (plasticity or brittleness) and μ/B assists in understanding flow and fracture mechanisms, and in guiding alloy design to alleviate brittleness of metallic glasses.

Effects of matrix microstructure and particle distribution on fracture of an aluminum metal matrix composite

Abstract This paper presents the results of a study on the effects of matrix microstructure and particle distribution on the fracture of an aluminum alloy metal matrix composite containing 20% by volume SiC particulate. The matrix microstructure was systematically varied by heat treating to either an under- or over-aged condition of equivalent strength, and was characterized using a combination of techniques. Quantitative metallographic techniques were utilized to characterize the material with respect to size, size distribution, and particle clustering, while transmission electron microscopy was utilized to characterize the details of the matrix microstructure in addition to the effects of aging on the character of the particle/matrix interfaces. Fracture experiments were conducted on smooth tensile, notched bend, shortrod toughness, and on specimens designed to permit controlled crack propagation, in an attempt to determine the effects of matrix microstructure and clustered regions on the details of damage accumulation. Large effects of microstructure on the notched properties were obtained with little effect of microstructure on tensile ductility. It is shown that the micromechanisms of fracture are significantly affected by the details of the matrix microstructure, interface character, and degree of clustering in the material. Fracture of the SiC was predominant in the underaged materials, with a preference for failure in the matrix and near the interface in the overaged material. Metallographic and fractographic analyses revealed that clustered regions were preferred sites for damage initiation in both the aging conditions tested, while preliminary results additionally indicate that damage accumulation ahead of a propagating crack also tended to occur in clustered regions.

Strength and ductile-phase toughening in the two-phase Nb/Nb5Si3 alloys

The effect of heat treatment on the mechanical properties of Nb-Nb5-Si3 two-phase alloys having compositions Nb-10 and 16 pct Si (compositions quoted in atomic percent) has been investigated. This includes an evaluation of the strength, ductility, and toughness of as-cast and hot-extruded product forms. The two phases are thermochemically stable up to ∼1670 °C, exhibit little coarsening up to 1500 °C, and are amenable to microstructural variations, which include changes in morphology and size. The measured mechanical properties and fractographic analysis indicate that in the extruded condition, the terminal Nb phase can provide significant toughening of the intermetallic Nb5Si3 matrix by plastic-stretching, interface-debonding, and crack-bridging mechanisms. It has been further shown that in these alloys, a high level of strength is retained up to 1400 °C.

Fracture toughness and notched toughness of bulk amorphous alloy: Zr-Ti-Ni-Cu-Be

Recent successes in producing bulk amorphous alloys have renewed interest in this class of materials. Although amorphous metallic alloys have been shown to exhibit strengths in excess of 2.0 GPa, most of the earlier studies on such materials were conducted on tape or ribbon specimens due to the high cooling rates required to achieve the amorphous structure. The primary purpose of this investigation was to determine the fracture toughness of a bulk metallic glass utilizing conventional procedures typically conducted with engineering materials. In particular, the effects of changes in the notch root radius from 250 {micro}m to a fatigue precrack on the toughness were determined. It is shown presently that the average toughness obtained from 6 fatigue precracked specimens was 18.4 {+-} 1.4 MPa {radical}m, while the notch toughness obtained on specimens with notch root radii ranging from 65 {micro}m-250 {micro}m were in the range of 101--131 MPa{radical}m.

Crack initiation and growth toughness of an aluminum metal-matrix composite

Abstract The effects of systematic changes in matrix microstructure on crack initiation and growth toughnesses were determined on an AlZnMgCu alloy containing 0, 15, 20% by volume of SiC particulates. Materials were heat treated to underaged (UA) and overaged (OA) conditions of equivalent matrix microhardness and flow stress. Although both the fracture initiation and growth toughnesses, as measured by J Ic and tearing modulus, were similar for the unreinforced materials in the UA and OA conditions, significant effects of microstructure on both J Ic and tearing modulus were observed in the composites. SEM and TEM observations of fracture paths in the two conditions are utilized to rationalize these observations in light of existing theories of ductile fracture propagation.

Effects of hydrostatic pressure on the flow and fracture of a bulk amorphous metal

Abstract The flow and fracture behaviour of a Zr-Ti-Ni-Cu-Be bulk amorphous metal have been determined in tension and compression at room temperature with levels of superimposed hydrostatic pressure ranging from 0.1 to 700 MPa. Metallographically polished cylindrical specimens tested in uniaxial tension and compression were utilized in the high pressure tests, while polished cylindrical torsion specimens were tested at 0.1 MPa (i.e. atmospheric pressure) in order to approach conditions of pure shear. All the tension and torsion tests, regardless of the level of superimposed pressure, exhibited linear elastic failure, as did the compression tests conducted with low levels (e.g. less than 450 MPa) of pressure. At the highest pressures (i.e. 450 MPa or higher), the compression tests exhibited elastic-perfectly plastic behaviour and an increase in the compressive elongation to fracture. The flow stress and fracture stress were not significantly affected by the superposition of pressure as failure occurred in shear, indicative of pressure-independent behaviour over the range tested. However, a change in fracture plane angle was detected. Tensile fracture surfaces were oriented at 50–59°; compression fracture surfaces were oriented at 40°. The flow and fracture behaviours were analysed in terms of a Mohr-Coulomb criterion of the form τc = 950 MPa - 0.038ω;n over the range of stress states examined. The results are discussed in the light of the various yield criteria and the flow and fracture theories provided for amorphous metallic systems.

Effects of heat treatment and reinforcement size

The effects of heat-treatment, matrix microstructure, and reinforcement size on the evolution of damage, in the form of SiCp cracking, during uniaxial tension testing of an aluminum-alloy based composite have been determined. A powder metallurgy Al-Zn-Mg-Cu alloy reinforced with 15 vol pct of either 5 or 13 μm average size SiCp was heat treated to solution annealed (SA), underaged (UA), and overaged (OA) conditions. The SA treatment exhibited lower yield strength and higher ductility for both particulate sizes compared to the UA and OA conditions. The evolution of damage, in the form of SiCp fracture, was monitored quantitatively using metallography and changes in modulus on sequentially strained specimens. It is shown that the evolution of SiCp fracture is very dependent on particulate size, matrix aging condition, and the details of the matrix-reinforcement interfacial regions. SiCp fracture was exhibited by the UA and OA treatment over a range of strains, while a preference for failure near the SiCp/matrix interfaces and in the matrix was exhibited in the OA material. While thepercentage of cracked SiCp at each global strain typically was equal or somewhat lower in the material reinforced with 5 μm average size SiCp, theabsolute number of cracked SiCp was always higher at each global stress and strain in the material containing 5 μm average size SiCp, for each heat treatment. Damage(e.g., voids) in the matrix and near the SiCp/matrix interfaces was additionally observed, although its extent was highly matrix and particle-size dependent. It was always observed that increases in stress (and strain) produced a larger amount of fractured SiCp. However, neither a global stress-based nor a global strain-based model was sufficient in converging the amount of SiCp fractured for all heat treatments and particle sizes tested.

Tough Fe-based bulk metallic glasses

The toughness of Fe-based bulk metallic glasses (BMGs) has been significantly improved via systematic changes in chemistry. Chemistry changes were selected based on their likely effects on critical elastic constants shown to affect plasticity/toughness in various BMGs, in addition to their recently discovered effects on chemical bonding in these Fe-based systems. The fracture energy obtained on notched toughness samples tested in mode I was correlated with chemistry-induced changes to Poisson’s ratio ν and the ratio of the elastic shear modulus μ to the bulk modulus B, as was the strain energy at fracture for smooth cylindrical compression samples that failed under mode II conditions. Fractographic observations correlate well with the observed increases in toughness.

Microstructural effects on the cleavage fracture stress of fully pearlitic eutectoid steel

The microstructural parameter(s) controlling the critical cleavage fracture stress, σF, of fully pearlitic eutectoid steel have been investigated. Independent variation of the pearlite interlamellar spacing,Sp, and the prior austenite grain size were accomplished through heat treatment. Critical cleavage fracture stresses were measured on bluntly-notched bend specimens tested over the temperature range -125 °C to 23 °C. The cleavage fracture stress increased with decreasingSp, and was independent of prior austenite grain size. Fine pearlitic microstructures exhibited temperature, strain-rate, and notched-bar geometry independent values for σF, consistent with propagation-controlled cleavage fracture. Coarse pearlitic specimens exhibited temperature-dependent values for σF over a similar temperature range. Inclusion-initiated fractures were generally located at or beyond the location of the peak normal stress in the bend bar, while cracking associated with pearlite colonies was observed to be closer to the notch than the predicted peak stress location. The calculated values for σF were independent of both the type and location of initiation site(e. g., inclusion, pearlite colony). Thus, although inclusions may provide potent fracture initiation sites, their presence or absence does not necessarily change σF in fully pearlitic microstructures.

Deformation and fracture toughness of a bulk amorphous Zr–Ti–Ni–Cu–Be alloy

Abstract The flow behavior and fracture toughness of two different plate thicknesses (i.e. 4 and 7 mm) of a bulk amorphous Zr–Ti–Ni–Cu–Be alloy was investigated. It is shown that the flow/fracture stress was independent of superimposed hydrostatic pressure over the range 50–575 MPa, suggesting that the flow behavior follows the von Mises criterion. However, the macroscopic orientation of the fracture plane relative to the stress axis was strongly affected by changes in stress state, suggesting some normal stress dependence to the flow/fracture behavior. The fracture behavior was also studied on both notched and precracked bend bars for both plate thicknesses. The average fracture toughness obtained from seven fatigue precracked specimens taken for both plate thicknesses was 17.9±1.8 MPa√m, while the notched toughness obtained on specimens with notch root radii ranging from 65 to 250 μm taken from both plate thicknesses were in the range of 9l–131 MPa√m.