Steven M. Arnold

Higher-Order Theory for Functionally Graded Materials

This paper presents the full generalization of the Cartesian coordinate-based higher-order theory for functionally graded materials developed by the authors during the past several years. This theory circumvents the problematic use of the standard micromechanical approach, based on the concept of a representative volume element, commonly employed in the analysis of functionally graded composites by explicitly coupling the local (microstructural) and global (macrostructural) responses. The theoretical framework is based on volumetric averaging of the various field quantities, together with imposition of boundary and interfacial conditions in an average sense between the subvolumes used to characterize the composites functionally graded microstructure. The generalization outlined herein involves extension of the theoretical framework to enable the analysis of materials characterized by spatially variable microstructures in three directions. Specialization of the generalized theoretical framework to previously published versions of the higher-order theory for materials functionally graded in one and two directions is demonstrated. In the applications part of the paper we summarize the major findings obtained with the one-directional and two-directional versions of the higher-order theory. The results illustrate both the fundamental issues related to the influence of microstructure on microscopic and macroscopic quantities governing the response of composites and the technologically important applications. A major issue addressed herein is the applicability of the classical homogenization schemes in the analysis of functionally graded materials. The technologically important applications illustrate the utility of functionally graded microstructures in tailoring the response of structural components in a variety of applications involving uniform and gradient thermomechanical loading.

Higher-order theory for periodic multiphase materials with inelastic phases

Abstract An extension of a recently-developed linear thermoelastic theory for multiphase periodic materials is presented which admits inelastic behavior of the constituent phases. The extended theory is capable of accurately estimating both the effective inelastic response of a periodic multiphase composite and the local stress and strain fields in the individual phases. The model is presently limited to materials characterized by constituent phases that are continuous in one direction, but arbitrarily distributed within the repeating unit cell which characterizes the materials periodic microstructure. The models analytical framework is based on the homogenization technique for periodic media, but the method of solution for the local displacement and stress fields borrows concepts previously employed by the authors in constructing the higher-order theory for functionally graded materials, in contrast with the standard finite-element solution method typically used in conjunction with the homogenization technique. The present approach produces a closed-form macroscopic constitutive equation for a periodic multiphase material valid for both uniaxial and multiaxial loading. The models predictive accuracy in generating both the effective inelastic stress-strain response and the local stress and inelastic strain fields is demonstrated by comparison with the results of an analytical inelastic solution for the axisymmetric and axial shear response of a unidirectional composite based on the concentric cylinder model and with finite-element results for transverse loading.

Thermoelastic theory for the response of materials functionally graded in two directions

A recently developed micromechanical theory for the thermoelastic response of functionally graded composites with nonuniform fiber spacing in the through-thickness direction is further extended to enable analysis of material architectures characterized by arbitrarily nonuniform fiber spacing in two directions. In contrast to currently employed micromechanical approaches applied to functionally graded materials, which decouple the local and global effects by assuming the existence of a representative volume element at every point within the composite, the new theory explicitly couples the local and global effects. The analytical development is based on volumetric averaging of the various field quantities, together with imposition of boundary and interfacial conditions in an average sense. Results are presented that illustrate the capability of the derived theory to capture local stress gradients at the free edge of a laminated composite plate due to the application of a uniform temperature change. It is further shown that it is possible to reduce the magnitude of these stress concentrations by a proper management of the microstructure of the composite plies near the free edge. Thus by an appropriate tailoring of the microstructure it is possible to reduce or prevent the likelihood of delamination at free edges of standard composite laminates.

Linear Thermoelastic Higher-Order Theory for Periodic Multiphase Materials

A new micromechanics model is presented which is capable of accurately estimating both the effective elastic constants of a periodic multiphase composite and the local stress and strain fields in the individual phases. The model is presently limited to materials characterized by constituent phases that are continuous in one direction, but arbitrarily distributed within the repeating unit cell which characterizes the materials periodic microstructure. The models analytical framework is based on the homogenization technique for periodic media, but the method of solution for the local displacement and stress fields borrows concepts previously employed by the authors in constructing the higher-order theory for functionally graded materials, in contrast with the standard finite element solution method typically used in conjunction with the homogenization technique. The present approach produces a closed-form macroscopic constitutive equation for a periodic multiphase material valid for both uniaxial and multiaxial loading which, in turn, can be incorporated into a structural analysis computer code. The models predictive accuracy is demonstrated by comparison with reported results of detailed finite element analyses of periodic composites as well as with the classical elasticity solution for an inclusion in an infinite matrix.

Response of functionally graded composites to thermal gradients

Abstract A new micromechanical theory is presented for the response of functionally graded metal-matrix composites subjected to thermal gradients. In contrast to existing micromechanical theories that utilize standard homogenization schemes in the course of calculating microscopic and macroscopic field quantities, in the present approach the actual microstructural details are explicitly coupled with the macrostructure of the composite. The theory is particularly well-suited for predicting the response of thin-walled metal-matrix composites with a finite number of large-diameter fibers in the thickness direction subjected to thermal gradients. Standard homogenization techniques which decouple micromechanical and macromechanical analyses may not produce reliable results for such configurations. Examples presented illustrate the usefulness of the outlined approach in generating favorable stress distributions in the presence of thermal gradients by appropriately grading the internal microstructural details of the composite.

On the thermodynamic framework of generalized coupled thermoelastic-viscoplastic-damage modeling

A complete potential based framework utilizing internal state variables is put forth for the derivation of reversible and irreversible constitutive equations. In this framework, the existence of the total (integrated) form of either the (Helmholtz) free energy or the (Gibbs) complementary free energy are assumed a priori. Two options for describing the flow and evolutionary equations are described, wherein option one (the fully coupled form) is shown to be over restrictive and the second option (the decoupled form) provides significant flexibility. As a consequence of the decoupled form, a new operator, that is, the compliance operator, is defined, which provides a link between the assumed Gibbs and complementary dissipation potential and ensures a number of desirable numerical features, for example, the symmetry of the resulting consistent tangent stiffness matrix. An important conclusion reached is that although many theories in the literature do not conform to the general potential framework outlined, it is still possible in some cases, by slight modifications of the employed forms, to restore the complete potential structure.

Elastic response of metal matrix composites with tailored microstructures to thermal gradients

Abstract A new micromechanical theory is presented for the response of heterogeneous metal matrix composites subjected to thermal gradients. In contrast to existing micromechanical theories that utilize classical homogenization schemes in the course of calculating microscopic and macroscopic field quantities, in the present approach the actual microstructural details are explicitly coupled with the macrostructure of the composite. Examples are offered that illustrate limitations of the classical homogenization approach in predicting the response of thin-walled metal matrix composites with large-diameter fibers to thermal gradients. These examples include composites with a finite number of fibers in the thickness direction that may be uniformly or nonuniformly spaced, thus admitting so-called functionally gradient composites. The results illustrate that the classical approach of decoupling micromechanical and macromechanical analyses in the presence of a finite number of large-diameter fibers, finite dimensions of the composite, and temperature gradient may lead to serious errors in the calculation of both macroscopic and microscopic field quantities. The usefulness of the new outlined approach in generating favorable stress distributions in the presence of thermal gradients by appropriately tailoring the internal microstructural details of the composite is also demonstrated.

Limitations of the uncoupled, RVE-based micromechanical approach in the analysis of functionally graded composites

Abstract A new class of materials, called functionally graded composites, has recently evolved in which the microstructure is tailored to meet specific applications. This is accomplished by distributing the reinforcement phases in a nonuniform manner, resulting in statistically inhomogeneous composites. The standard micromechanical approach used to analyse the response of this class of materials is to decouple the local and global effects by assuming the existence of a representative volume element at every point within the composite. Recently, a new micromechanical theory, which couples the local and global effects, has been developed and applied to functionally graded composites. Herein, this theory is used to assess the limits of applicability of the standard micromechanical approach in predicting local stresses in the fiber and matrix phases of functionally graded composites subjected to a thermal gradient. It is shown that the simplified uncoupled approach is inaccurate when the dimension of the reinforcement phase is large relative to the dimension of the composite.

A general hereditary multimechanism-based deformation model with application to the viscoelastoplastic response of titanium alloys

Abstract The formulation of a general model for the hereditary behavior of materials, in the viscoelastic and viscoplastic regimes, is presented. In this, we utilize the complete-potential structure as a general framework, together with the notion of strain- and stress- partitioning in terms of separate contributions of several submechanisms (viscoelastic and viscoplastic) to the thermodynamic functions (stored energy and dissipation). Detailed numerical treatments are given for both (i) the implicit integration algorithm for the governing flow and evolutionary rate equations of the model, and (ii) the automated parameter-estimation methodology (using the software code COMPARE) for characterization. For illustration, a specific form of the model presented is characterized for the TIMETAL 21S material using a very comprehensive test matrix, including creep, relaxation, constant strain-rate tension tests, etc. Discussion of these correlations tests, together with comparisons to several other experimental results, are given to assess the performance and predictive capabilities of the present model as well as the effectiveness and practical utility of the algorithms proposed.

The effect of interface roughness and oxide film thickness on the inelastic response of thermal barrier coatings to thermal cycling

Abstract The effects of interfacial roughness and oxide film thickness on thermally-induced stresses in plasma-sprayed thermal barrier coatings subjected to thermal cycling are investigated using the recently developed higher-order theory for functionally graded materials. The higher-order theory is shown to be a viable alternative to the finite-element approach, capable of modeling different interfacial roughness architectures in the presence of an aluminum oxide layer and capturing the high stress gradients that occur at the top coat–bond coat interface. The oxide layer thickness is demonstrated to have a substantially greater effect on the evolution of residual stresses than local variations in interfacial roughness. Further, the location of delamination initiation in the top coat is predicted to change with increasing oxide layer thickness. This result can be used to optimize the thickness of a pre-oxidized layer introduced at the top coat–bond coat interface in order to enhance TBC durability as suggested by some researchers. The results of our investigation also support a recently proposed hypothesis regarding delamination initiation and propagation in the presence of an evolving bond coat oxidation, while pointing to the importance of interfacial roughness details and specimen geometry in modeling this phenomenon.