Abstract

Multiple strain path changes during forming lead to complex geometrically necessary dislocation (GND) development in strain gradient fields, inducing internal stresses that contribute to the Bauschinger effect, residual stresses, and springback which alters the final geometrical shape of the part. In order to analyze and design improved processing routes, models must capture the evolution of these internal stresses. However, most models capture the effects of these stresses via phenomenological approaches that require calibration to each new material and strain path. The development of models that capture the underlying physics at the sub-grain level is underway but requires in-depth studies of dislocation behavior (at the relevant meso length scale) in order to guide and validate them. The novel experimental campaign central to this thesis aims to tackle this problem by capturing unprecedented data of dislocation activity for several sheet metals during multiple strain path deformation. The resultant insights provide a new window into multi-path forming of metals, while also aiding the development and validation of two crystal plasticity (CP) models by collaborators at the University of New Hampshire (UNH). The models incorporate internal stresses at the grain and sub-grain levels, respectively. The hardening response due to strain path change during forming of AA6016-T4 was studied at the macro- and micro-level via combined experiments and an elasto-plastic self-consistent (EPSC) model. The experiments demonstrated that possible recombination and/or redirection of dislocations onto different slip systems under strain path change allowed for a gradual elasto-plastic transition, in comparison to a much sharper response upon continued deformation under the same strain path due to buildup and immediate activation of backstresses. The phenomenological backstress law of the EPSC model underpredicted the yield stress response for the strain path change deformations, possibly due to missing sub-grain GND development and an accurate description of associated backstresses. A more detailed experimental study of multi-path deformation for the AA6016-T4 was required in order to guide development of a strain gradient elasto-visco plasticity self-consistent model (SG-EVPSC); the model includes sub-grain strain gradient fields, and related internal stress fields. Total dislocation and GND density were tracked at various points of the deformation, and a complete 3D statistical volume element was characterized, to enable accurate modeling of the microstructure. The tests revealed a relatively lower yield stress response following strain path change, presumably aided by lower latent hardening than self hardening; the tests then showed a rapid accumulation of dislocations on the newly activated slip systems resulting in much higher final dislocation density without affecting the ductility of the pre-strained material. Interestingly, GND development was dominated by the precipitates instead of grain boundaries. These observations are vital for an accurate forming prediction from CPFEA models. Finally, optimized forming conditions of continuous bending under tension produced a ratcheting strain path resulting in a gradual GND development and a more complete retained austenite transformation in quenched-&-partitioned- and TRIP-assisted bainitic ferritic-1180 steels increasing their ductility by at least 360%.

Degree

PhD

College and Department

Ira A. Fulton College of Engineering; Mechanical Engineering

Rights

https://lib.byu.edu/about/copyright/

Date Submitted

2022-12-02

Document Type

Dissertation

Handle

http://hdl.lib.byu.edu/1877/etd13008

Keywords

GND, SSD, backstress, multi-strain, XRD, aluminum alloy, AHSS, Burgers vector

Language

english

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Engineering Commons

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