Numerical, experimental, nondestructive, and image analyses of damage; progression in cast A356 aluminium notch tensile bars

Void nucleation, growth, and coalescence in A356 aluminum notch specimens was determined from a combination of experiments, finite element analysis, nondestructive analysis, and image analysis. Notch Bridgman tension experiments were performed on specimens to failure and then other specimens were tested to 90%, 95%, and 98% of the failure load. The specimens were evaluated with nondestructive X-ray tomography and optical image analysis. Finite element simulations of the notch tests were performed with an elastic–plastic internal state variable material model that incorporated the pertinent microstructures (silicon particle volume fraction and size distribution and porosity volume fraction and size distribution). Parametric finite element simulations were performed to give insight into various initial conditions and responses of the notch tensile bars. The various methods all corroborated the same damage progression.

[1]  G. T. Hahn,et al.  Metallurgical factors affecting fracture toughness of aluminum alloys , 1975 .

[2]  M. Ashby Work hardening of dispersion-hardened crystals , 1966 .

[3]  John W. Hutchinson,et al.  Void Growth and Collapse in Viscous Solids , 1982 .

[4]  Asim Tewari,et al.  MODELING OF NON-UNIFORM SPATIAL ARRANGEMENT OF FIBERS IN A CERAMIC MATRIX COMPOSITE , 1997 .

[5]  J. P. Hirth,et al.  Analysis of cavity nucleation in solids subjected to external and internal stresses , 1985 .

[6]  R. McMeeking,et al.  Void Growth in Elastic-Plastic Materials , 1989 .

[7]  Mark F. Horstemeyer,et al.  Micromechanical finite element calculations of temperature and void configuration effects on void growth and coalescence , 2000 .

[8]  F. H. Samuel,et al.  A metallographic study of porosity and fracture behavior in relation to the tensile properties in 319.2 end chill castings , 1995 .

[9]  Alan Needleman,et al.  Void nucleation effects on shear localization in porous plastic solids , 1982 .

[10]  Mark F. Horstemeyer,et al.  On Factors Affecting Localization and Void Growth in Ductile Metals: A Parametric Study , 2000 .

[11]  Viggo Tvergaard,et al.  Ductile fracture by cavity nucleation between larger voids , 1982 .

[12]  J. Im,et al.  Cavity formation from inclusions in ductile fracture , 1975 .

[13]  F. A. McClintock,et al.  A Criterion for Ductile Fracture by the Growth of Holes , 1968 .

[14]  G. Smith,et al.  FRACTURE OF INTERNALLY OXIDIZED COPPER ALLOYS. , 1968 .

[15]  Mark F. Horstemeyer,et al.  Stress History Dependent Localization and Failure Using Continuum Damage Mechanics Concepts , 1997 .

[16]  A. Needleman A Continuum Model for Void Nucleation by Inclusion Debonding , 1987 .

[17]  Mark F. Horstemeyer,et al.  A Numerical Parametric Investigation of Localization and Forming Limits , 2000 .

[18]  F. A. Leckie,et al.  Creep problems in structural members , 1969 .

[19]  A. Gurson Continuum Theory of Ductile Rupture by Void Nucleation and Growth: Part I—Yield Criteria and Flow Rules for Porous Ductile Media , 1977 .

[20]  D. M. Tracey,et al.  On the ductile enlargement of voids in triaxial stress fields , 1969 .

[21]  Arun M. Gokhale,et al.  Application of image analysis for characterization of spatial arrangements of features in microstructure , 1995 .

[22]  van der Erik Giessen,et al.  SIMULATION OF MATERIALS PROCESSING: THEORY, METHODS AND APPLICATIONS , 1998 .

[23]  J. Rice,et al.  Limits to ductility set by plastic flow localization , 1978 .

[24]  Arun M. Gokhale,et al.  Computer simulation of spatial arrangement and connectivity of particles in three-dimensional microstructure: Application to model electrical conductivity of polymer matrix composite , 1996 .

[25]  V. Tvergaard On localization in ductile materials containing spherical voids , 1982, International Journal of Fracture.

[26]  M. Zaidman,et al.  Constitutive models for porous materials with evolving microstructure , 1994 .

[27]  Mark F. Horstemeyer,et al.  A void–crack nucleation model for ductile metals , 1999 .

[28]  A. Miller A unified approach to predicting interactions among creep, cyclic plasticity, and recovery☆ , 1978 .

[29]  A. Rosenfield Criteria for ductile fracture of two-phase alloys , 1968 .

[30]  S. H. Goods,et al.  THE NUCLEATION OF CAVITIES BY PLASTIC DEFORMATION , 1983 .

[31]  Michael F. Ashby,et al.  Intergranular fracture at elevated temperature , 1975 .

[32]  Z. Mroz,et al.  On the criterion of damage evolution for variable multiaxial stress states , 1998 .

[33]  J. Yeh,et al.  The cracking mechanism of silicon particles in an A357 aluminum alloy , 1996 .

[34]  V. Tvergaard Material Failure by Void Growth to Coalescence , 1989 .

[35]  S. H. Goods,et al.  Overview No. 1: The nucleation of cavities by plastic deformation , 1979 .

[36]  T. B. Cox,et al.  An investigation of the plastic fracture of AISI 4340 and 18 Nickel-200 grade maraging steels , 1974, Metallurgical and Materials Transactions B.

[37]  Quantitative characterization of spatial arrangement of micropores in cast microstructures , 1998 .

[38]  Elias C. Aifantis,et al.  A damage model for ductile metals , 1989 .

[39]  J. Gurland,et al.  Observations on the fracture of cementite particles in a spheroidized 1.05% c steel deformed at room temperature , 1972 .

[40]  M. F. Ashby,et al.  On creep fracture by void growth , 1982 .

[41]  Torsional Softening and the Forming Limit Diagram , 1996 .

[42]  J. Gurland,et al.  THE MECHANISM OF DUCTILE RUPTURE OF METALS CONTAINING INCLUSIONS , 1963 .

[43]  J. R. Griffiths,et al.  The deformation and fracture behaviour of an AlSiMg casting alloy , 1995 .

[44]  A. Cocks Inelastic deformation of porous materials , 1989 .

[45]  V. Tvergaard Material failure by void coalescence in localized shear bands , 1982 .

[46]  J. Rice Inelastic constitutive relations for solids: An internal-variable theory and its application to metal plasticity , 1971 .

[47]  R. Borst Smeared cracking, plasticity, creep, and thermal loading—A unified approach , 1987 .

[48]  Mark F. Horstemeyer,et al.  Modeling stress state dependent damage evolution in a cast Al–Si–Mg aluminum alloy , 2000 .

[49]  M. Horstemeyer,et al.  High temperature sensitivity of notched AISI 304L stainless steel tests , 1998 .