Rheological Behavior of Al-Cu Alloys during Solidification: Constitutive Modeling, Experimental Identification, and Numerical Study

The rheological behavior of a solidifying alloy is modeled by considering the deforming material as a viscoplastic porous medium saturated with liquid. Since the solid grains in the mush do not form a fully cohesive skeleton, an internal variable that represents the partial cohesion of this porous material is introduced. The model parameters are identified using shear and compressive stress states under isothermal conditions on an Al-Cu model alloy. The model is partially validated with onisothermal conditions and we complete this study with tensile conditions. Such conditions, when applied on the mush, may lead to severe defects in many casting processes. The model has been implemented into a commercial finite-element code to simulate a tensile test. Comparison with experimental data shows that the model is able to reproduce the main features of a solidifying alloy under tension, although fracture is not directly addressed here. We show that two critical solid fractions must be introduced in the model to account for the rheology: the coherency solid fraction at which the mush acquires significant strength and the coalescence solid fraction at which solid grains start to form solid bridges.

Non-isothermal tensile tests during solidification of Al–Mg–Si–Cu alloys: Mechanical properties in relation to the phenomenon of hot tearing

Jean-Marie Drezet

An original set-up has been used to study the mechanical properties of aluminium alloys in tension during solidification with a high cooling rate (70 K/s). The mechanical behaviour of 6056 aluminium alloy with and without grain refiner has been investigated as well as that of mixtures between AA6056 and AA4047. The results show that the alloys exhibit a viscoplastic behaviour in the mushy state. A transition is observed between fracture in the mushy state and fracture in the solid state as a function of the displacement rate. This displacement rate at the transition depends on the cooling rate and on the composition of the alloy. The displacement before fracture is observed to be independent of displacement rate but to depend on the composition and on the solidification rate. Based on the observations a criterion for fracture in the mushy state is proposed. A simple rheological law describing the mechanical behaviour of the alloys is coupled to a finite element calculation giving the thermal field during the tensile test. This simulation is able to reproduce the mechanical response of the solidifying alloy during a non-isothermal test.

Elsevier2006

Probing the local strength and toughness of microscopic hard second phases in metals and composites

Marco Cantoni, Raphaël Charvet, Cyril Dénéréaz, Willy Dufour, Marta Fornabaio, Lionel Michelet, Andreas Mortensen, Martin Guillermo Mueller, Václav Pejchal, Goran Zagar

Many engineering alloys and composites combine a ductile matrix with discrete microscopic reinforcing phases, e.g. silicon particles in aluminium alloys, carbides in steels or ceramic particles in metal matrix composites. It is well understood that the mechanical properties of such alloys and composites are strongly influenced by those of their reinforcing particles; yet not much is known of the nature and size of strength-limiting flaws within such microscopic second phases. To investigate the strength and fracture toughness of these microscopic particles directly, we have developed test methods that combine focused ion beam (FIB) milling with microtesting techniques and bespoke finite element simulation. Local strength is probed by micromachining individual reinforcing particles in such a way that tensile stresses are produced in a volume of material free of FIB and polishing artifacts upon the application of a load via nanoindenter. Fracture toughness is measured by the chevron-notch fracture test technique adapted for microscopic samples. Testing methods are established using nanocrystalline alumina fibers as the testbench material, so as to compare data thus obtained with known fiber properties from tensile tests on long sections of the fibers. These test methods are currently being transposed towards the microscopic testing of more irregularly shaped and anisotropic brittle second phases, with the objective to measure their local mechanical properties and identify microstructural flaws that govern the strength of such particles, using in-depth electron microscopy characterization combined with microtesting.

2015

Probing the local strength and toughness of microscopic hard second phases in alloys and composites

Marco Cantoni, Raphaël Charvet, Cyril Dénéréaz, Willy Dufour, Marta Fornabaio, Lionel Michelet, Andreas Mortensen, Martin Guillermo Mueller, Václav Pejchal, Goran Zagar

Many engineering alloys and composites combine a ductile matrix with discrete microscopic reinforcing phases. It is known that the mechanical properties of such alloys and composites are strongly influenced by those of those reinforcing phases; however, surprisingly little is known of the toughness, or of strength-limiting flaws within those phases. To investigate the strength and fracture toughness of such microscopic particles directly, we have developed test methods that combine focused ion beam (FIB) milling with microtesting and bespoke finite element simulation. Local strength is measured using a nanoindenter probing micromachined samples carved into individual reinforcing particles in such a way that tensile stresses are produced in a volume of material that is free of FIB and polishing artifacts. Fracture toughness is measured using the chevron-notch fracture test technique adapted for microscopic samples. Testing methods are established using nanocrystalline alumina fibers as the testbench material, so as to compare data thus obtained with known fiber properties from tensile tests on long sections of the fibers. These test methods are now being transposed towards the microscopic testing of more irregularly shaped and anisotropic brittle second phases, while other tests are being developed to probe phases the shape of which enables the design of other tailored testing procedures.

2015