Static and Dynamic Properties of Al-Mg Alloys Subjected to Hydrostatic Extrusion

The aim of this study is to determine the influence of the amount of magnesium in Al-Mg alloys and strain rate on the grain refinement and mechanical properties of the material as determined in a dynamic tensile test. Hydrostatic extrusion was used to process the material. This method is not commonly used to impose severe plastic deformation of Al-Mg alloys. The article presents the results of static and dynamic strength tests on aluminium alloys subjected to plastic deformation in the hydrostatic extrusion process. Technically pure aluminium Al99.5 and three aluminium alloys with different magnesium content, Al-1Mg, Al-3Mg and Al-7.5Mg, were used in the tests. The samples were subjected to static tests using the uniaxial tensile test machine and dynamic tests using a rotary hammer. Compared to pure aluminium, increasing the magnesium content in Al-based alloys strengthened them in hydrostatic extrusion (logarithmic strain ε = 0.86) and caused an increase in the static ultimate tensile stress R_m, relative strain ε_r and the value of the yield stress. For strengthened aluminium alloys, an increase in the strain rate from 750 to 1750 s⁻¹ caused an increase in the dynamic ultimate tensile stress from 1.2 to 1.9 times in relation to the static ultimate tensile stress. The increase in magnesium content results in the formation of a larger strengthening phase, influences a different state of stress during dynamic loading and leads to a change in the orientation of the fracture surface. It was also found that an increase in magnesium content is associated with an increased number of voids, which is also directly proportional to the strain rate in the dynamic rotary hammer test.     

The Use of Aluminium Alloy after High Plastic Deformation for Joining Riveted Structures

This paper presents the results of a static and dynamic tensile test of an Al7.5Mg aluminium alloy taken from round bars made in the technology of hydrostatic extrusion. It is planned to use the Al7.5Mg aluminium alloy for joining riveted structures. Based on the obtained results, the nominal and true characteristics of the Al7.5Mg aluminium alloy, depending on the strain rate in the range from 0 to 2000 s⁻¹, were developed. The failure criterion for tension was determined. The material characteristics were approximated by the Johnson–Cook equation, which can be used in CAE (computer-aided engineering) programs to simulate the impact processes. FEM (finite element method) simulation of the impact of the hammer on the part of the riveted aircraft structure was performed. The FEM simulation results were compared with the experimental results on a drop hammer to verify the material model. The following results were obtained: yield strength R_e = 395.3 MPa; strength limit R_m = 523.1 MPa at deformation 0.067; Young’s modulus E = 7.9 × 10⁴ MPa. The AL7.5Mg alloy after hydro-extrusion has favourable plastic and strength properties.     

Probabilistic Finite Element Modeling of Textile Reinforced SHCC Subjected to Uniaxial Tension

The paper presents a finite element investigation of the effect of material composition and the constituents’ interaction on the tensile behavior of strain-hardening cement-based composites (SHCC) both with and without textile reinforcement. The input material parameters for the SHCC and continuous reinforcement models, as well for their bond, were adopted from reference experimental investigations. The textile reinforcement was discretized by truss elements in the loaded direction only, with the constitutive relationships simulating a carbon and a polymer textile, respectively. For realistic simulation of macroscopic tensile response and multiple cracking patterns in hybrid fiber-reinforced composites subjected to tension, a multi-scale and probabilistic approach was adopted. SHCC was simulated using the smeared crack model, and the input constitutive law reflected the single-crack opening behavior. The probabilistic definition and spatial fluctuation of matrix strength and tensile strength of the SHCC enabled realistic multiple cracking and fracture localization within the loaded model specimens. Two-dimensional (2D) simulations enabled a detailed material assessment with reasonable computational effort and showed adequate accuracy in predicting the experimental findings in terms of macroscopic stress–strain properties, extent of multiple cracking, and average crack width. Besides material optimization, the model is suitable for assessing the strengthening performance of hybrid fiber-reinforced composites on structural elements.     

Experimental Study on the Axial Tensile Properties of FRP Grid-Reinforced ECC Composites

The axial tensile properties of FRP mesh-reinforced ECC composites (TRE) were investigated experimentally under the consideration of four influencing factors: grid type, number of reinforcement layers, ECC matrix thickness, and sticky sand treatment on the grid surface. The test results showed that the axial stiffness and tensile strength of the composite were significantly increased, and the tensile properties were significantly improved under the effect of FRP grid reinforcement. Increasing the thickness of the ECC matrix can obviously improve the crack resistance of composites. The ultimate tensile strength of FRP lattice-reinforced ECC composites increased significantly with the increase in the number of lattice layers, but had no significant effect on the crack resistance. The tensile properties of CFRP grid-reinforced ECC composites were slightly better compared to BFRP grid-reinforced ECC composites. The crack resistance and ultimate tensile strength of the composites were slightly improved by impregnating the surface of the FRP grid with adhesive-bonded sand treatment. Based on the experimental data, the tensile stress–strain constitutive model of FRP grid-reinforced ECC composites is established. The calculation results show that the theoretical values of the model agree well with the experimental values. Therefore, it can be used to reflect the stress–strain change state of FRP lattice-reinforced ECC composites during axial tension.     

Mathematical Model of Constitutive Relation and Failure Criteria of Plastic Concrete under True Triaxial Compressive Stress

To establish the mathematic model of the constitutive relation and failure criteria of plastic concrete under true triaxial compressive stress, uniaxial compressive strength and true triaxial compressive strength of plastic concrete under three kinds of confining pressures with a size of 150 × 150 × 150 mm³ and a curing age of 540 days were tested, and the elastic modulus of plastic concrete with a size of 150 × 150 × 300 mm³ and a curing age of 90 days was tested. Based on the database, under uniaxial compressive stress tests and true triaxial compressive stress tests, the mathematic model of constitutive relation and the failure criteria of plastic concrete were investigated. It was observed that the strength of plastic concrete increased with confining stress. The mathematic model of constitutive relation in the form of the quartic polynomial is in good agreement with measured data. The general equations of failure criteria based on the octahedral stress-space under true triaxial compressive stress in the form of quadratic polynomial are well-fitting with experimental data. The mathematic model of constitutive relation and failure criteria of plastic concrete could provide the basis for a numerical simulation analysis of plastic concrete under true triaxial compressive stress, as well as promote the engineering application of plastic concrete.     

Low Cycle Fatigue Life Assessment Based on the Accumulated Plastic Strain Energy Density

The accumulated plastic strain energy density at a dangerous point is studied to estimate the low cycle fatigue life that is composed of fatigue initiation life and fatigue crack propagation life. The modified Ramberg–Osgood constitutive relation is applied to characterize the stress–strain relationship of the strain-hardening material. The plastic strain energy density under uni-axial tension and cyclic load are derived, which are used as threshold and reference values, respectively. Then, a framework to assess the lives of fatigue initiation and fatigue crack propagation by accumulated plastic strain energy density is proposed. Finally, this method is applied to two types of aluminum alloy, LC9 and LY12 for low-cycle fatigue, and agreed well with the experiments.     

Calculation Derivation and Test Verification of Indirect Tensile Strength of Asphalt Pavement Interlayers at Low Temperatures

When the direct tensile test is adopted to determine the interlayer tensile strength of the asphalt pavements, specimen separation or internal cracking often occurs at the bonding area of the loading head, rather than at the interlaminar bonding interface. In view of the tedious and discrete data of the direct tensile test, this paper attempts to introduce an indirect tensile test to determine the interlayer bond strength of asphalt pavement to solve this problem. However, the indirect tensile test method of a binder lacks the corresponding mechanical theory. This paper deduces the calculation formula of the indirect tensile strength of a binder based on elastic theory. A mechanical model of the test was established with the finite element method. In accordance with the two-dimensional elastic theory and the Flamant solution, an analytical solution of tensile stress in the indirect tensile test is proposed through the stress superposition. On this basis, the calculation formula for the indirect tensile strength of the interlaminar bonding is derived according to Tresca’s law. A low-temperature indirect tensile test was designed and conducted to verify the correctness of the formula. By comparing the results of the indirect tensile test and direct tensile test, it is found that the interlaminar strength of the mixture measured by them is similar, and the dispersion of indirect tensile test results is small. The results show that the indirect tensile test can replace the direct tensile test to evaluate the interlaminar tensile strength.     

On the Dynamic Tensile Behaviour of Thermoplastic Composite Carbon/Polyamide 6.6 Using Split Hopkinson Pressure Bar

A dynamic tensile experiment was performed on a rectangular specimen of a non-crimp fabric (NCF) thermoplastic composite T700 carbon/polyamide 6.6 specimens using a split Hopkinson pressure (Kolsky) bar (SHPB). The experiment successfully provided useful information on the strain-rate sensitivity of the NCF carbon/thermoplastic material system. The average tensile strength at three varying strain rates: 700, 1400, and 2100/s was calculated and compared to the tensile strength measured from a standardized (quasi-static) procedure. The increase in tensile strength was found to be 3.5, 24.2, and 45.1% at 700, 1400, and 2100/s strain rate, respectively. The experimental findings were used as input parameters for the numerical model developed using a commercial finite element (FE) explicit solver LS-DYNA^®. The dynamic FE model was validated against experimental gathering and used to predict the composite system’s behavior in various engineering applications under high strain-rate loading conditions. The SHPB tension test detailed in this study provided the enhanced understanding of the T700/polyamide 6.6 composite material’s behavior under different strain rates and allowed for the prediction of the material’s behavior under real-world, dynamic loading conditions, such as low-velocity and high-velocity impact.     

Effect of Mechanical Heterogeneity on Strain and Stress Fields at Crack Tips of SCC in Dissimilar Metal Welded Joints

The crack tip strain and stress condition are one of the main factors affecting stress corrosion cracking (SCC) behaviors in the dissimilar metal welded joint of the primary circuit in the pressurized water reactor. The mechanical property mismatch of base metal and weld metal can significantly affect the stress and strain condition around the crack tip. To understand the effect of different weld metals on strain and stress fields at SCC crack tips, the effects of strength mismatch, work hardening mismatch, and their synergy on the strain and stress field of SCC in the bi-material interface, including plastic zone, stress state, and corresponding J-integral, are investigated in small-scale yielding using the finite element method. The results show a significant effect of the strength mismatch and work hardening mismatch on the plastic zone and stress state in the weld metal and a negligible effect in the base metal. J-integral decreases with the single increase in either strength mismatch or work hardening mismatch. Either the increase in strength mismatch or work hardening mismatch will inhibit the other’s effect on the J-integral, and a synthetic mismatch factor can express this synergistic effect.     

Finite Plane Strain Bending under Tension of Isotropic and Kinematic Hardening Sheets

The present paper provides a semianalytic solution for finite plane strain bending under tension of an incompressible elastic/plastic sheet using a material model that combines isotropic and kinematic hardening. A numerical treatment is only necessary to solve transcendental equations and evaluate ordinary integrals. An arbitrary function of the equivalent plastic strain controls isotropic hardening, and Prager’s law describes kinematic hardening. In general, the sheet consists of one elastic and two plastic regions. The solution is valid if the size of each plastic region increases. Parameters involved in the constitutive equations determine which of the plastic regions reaches its maximum size. The thickness of the elastic region is quite narrow when the present solution breaks down. Elastic unloading is also considered. A numerical example illustrates the general solution assuming that the tensile force is given, including pure bending as a particular case. This numerical solution demonstrates a significant effect of the parameter involved in Prager’s law on the bending moment and the distribution of stresses at loading, but a small effect on the distribution of residual stresses after unloading. This parameter also affects the range of validity of the solution that predicts purely elastic unloading.     

A Nonlinear Elastic Model for Compressible Aluminum Alloys with Finite Element Implementation

In this paper, a three-dimensional model of nonlinear elastic material is proposed. The model is formulated in the framework of Green elasticity, which is based on the specific elastic energy potential. Equivalently, this model can be associated to the deformation theory of plasticity. The constitutive relationship, derived from the assumed specific energy, divides the material’s behavior into two stages: the first one starts with an initial almost linear stress–strain relation which, for higher strain, smoothly turns into the second stage of hardening. The proposed relation mimics the experimentally observed response of ductile metals, aluminum alloys in particular. In contrast to the classic deformation theory of plasticity or the plastic flow theory, the presented model can describe metal compressibility in both stages of behavior. The constitutive relationship is non-reversible expressing stress as a function of strain. Special attention is given to the calibration process, in which a one-dimensional analog of the three-dimensional model is used. Various options of calibration based on uniaxial stress test are extensively discussed. A finite element code is written and verified in order to validate the model. Solutions of selected problems, obtained via ABAQUS, confirm the correctness of the model and its usefulness in numerical simulations, especially for buckling.     

Automatic Multi-Stage Cold Forging of an SUS304 Ball-Stud with a Hexagonal Hole at One End

SUS304 stainless steel is characterized by combined tensile and compression testing, with an emphasis on flow stress at higher strain and temperature. The plastic deformation behavior of SUS304 from room temperature to 400 °C is examined and a general approach is used to express flow stress as a closed-form function of strain, strain rate, and temperature; this is optimal when the strain is high, especially during automatic multi-stage cold forging. The fitted flow stress is subjected to elastothermoviscoplastic finite element analysis (FEA) of an automatic multi-stage cold forging process for an SUS304 ball-stud. The importance of the thermal effect during cold forging, in terms of high material strength and good strain-hardening, is revealed by comparing the forming load, die wear and die stress predictions of non-isothermal and isothermal FEAs. The experiments have shown that the predictions of isothermal FEA are not feasible because of the high predicted effective stress on the weakest part of the die.     

Experimental and Numerical Investigation of Tensile and Flexural Behavior of Nanoclay Wood-Plastic Composite

In this study, the effect of wood powder and nanoclay particle content on composites’ mechanical behavior made with polyethylene matrix has been investigated. The wood flour as a reinforcer made of wood powder was at levels of 30, 40, and 50 wt.%, and additional reinforcement with nanoclay at 0, 1, 3, and 5 wt.%. Furthermore, to make a composite matrix, high-density polyethylene was used at levels of 70, 60, and 50% by weight. Wood-plastic composite (WPC) specimens were manufactured in injection molding. After preparing the specimens, tensile and bending tests were performed on samples. The mechanical properties such as tensile and flexural strength and flexural modulus were measured. Results showed that nanoclay particle content increases flexural modulus, flexural strength, modulus of elasticity, and tensile strength. The experimental test results show that Young’s moduli increased with the volume of wood flour. The biggest modulus of elasticity was achieved in the samples having 50 wt.% of wood powder. Furthermore, the highest value of tensile strength was achieved at the level of 30 wt.%. The highest flexural strength was for the sample containing 50% wood powder by weight. Additionally, a numerical model was made utilizing the Abaqus software using the finite element method (FEM). Comparing the numerical and experimental results, it was found that they are compatible in the linear-elastic and plastic state of the material. There are no crucial differences between experiment and FEM.     

Liquid Metal Embrittlement of Advanced High Strength Steel: Experiments and Damage Modeling

In the automotive industry, corrosion protected galvanized advanced high strength steels with high ductility (AHSS-HD) gain importance due to their good formability and their lightweight potential. Unfortunately, under specific thermomechanical loading conditions such as during resistance spot welding galvanized, AHSS-HD sheets tend to show liquid metal embrittlement (LME). LME is an intergranular decohesion phenomenon leading to a drastic loss of ductility of up to 95%. The occurrence of LME for a given galvanized material mainly depends on thermal and mechanical loading. These influences are investigated for a dual phase steel with an ultimate tensile strength of 1200 MPa, a fracture strain of 14% and high ductility (DP1200HD) by means of systematic isothermal hot tensile testing on a Gleeble^® 3800 thermomechanical simulator. Based on the experimental findings, a machine learning procedure using symbolic regression is applied to calibrate an LME damage model that accounts for the governing quantities of temperature, plastic strain and strain rate. The finite element (FE) implementation of the damage model is validated based on the local damage distribution in the hot tensile tested samples and in an exemplary 2-sheet resistance spot weld. The developed LME damage model predicts the local position and the local intensity of liquid metal induced cracking in both cases very well.     

Numerical Simulation of Steel-Reinforced Reactive Powder Concrete Beam Based on Bond-Slip

In this study, based on the concrete damaged plasticity (CDP) model in the ABAQUS software, various plastic damage factor calculation methods were introduced to obtain CDP parameters suitable for reactive powder concrete (RPC) materials. Combined with the existing tests for the bending performance of steel-reinforced RPC beams, the CDP parameters of the RPC material were input into ABAQUS to establish a finite element model considering the bond and slip between the steel and RPC for numerical simulation. The load-deflection curve obtained by the simulation was compared with the measured curve in the experiment. The results indicated that on the basis of the experimentally measured RPC material eigenvalue parameters, combined with the appropriate RPC constitutive relationship and the calculation method of the plastic damage factor, the numerical simulation results considering the bond-slip were in good agreement with the experimental results with a deviation of less than 10%. Thus, it is recommended to select a gentle compressive stress-strain curve in the descending section, an approximate strengthening model of the tensile stress-strain curve, and to use the energy loss method and Sidoroff’s energy equivalence principle to calculate the RPC plastic damage parameters.     

Effects of Temperature on the Evolution of Yield Surface and Stress Asymmetry in A356–T7 Cast Aluminium Alloy

As the electrification of vehicle powertrains takes prominence to meet stringent emission norms, parts of internal combustion engines like cylinder heads are subjected to an increased number of thermal load cycles. The cost-effective design of such structures subjected to cyclic thermo-mechanical loads relies on the development of accurate material models capable of describing the continuum deformation behaviour of the material. This study investigates the effect of temperature on the evolution of flow stress under cyclic loading in A356-T7 + 0.5% Cu cast aluminium alloy commonly used in modern internal combustion engine cylinder heads. The material exhibits peak stress and flow stress asymmetry with the stress response and flow stress of the material under compressive loading higher than under tension. This peak and flow stress asymmetry decrease with an increase in temperature. To compare this stress asymmetry against conventional steel, cyclic strain-controlled fatigue tests are run on fully pearlitic R260 railway steel material. To study the effect of mean strain on the cyclic mean stress evolution and fatigue behaviour of the alloy, tests with tensile and compressive mean strains of +0.2% and −0.2% are compared against fully reversed (R_ε = −1) strain-controlled tests. The material exhibits greater stress asymmetry between the peak tensile and peak compressive stresses for the strain-controlled tests with a compressive mean strain than the tests with an identical magnitude tensile mean strain. The material exhibits mean stress relaxation at all temperatures. Reduced durability of the material is observed for the tests with tensile mean strains at lower test temperatures of up to 150 °C. The tensile mean strains at elevated temperatures do not exhibit such a detrimental effect on the endurance limit of the material.     

Cyclic Behavior of Reinforced High Strain-Hardening UHPC under Axial Tension

The cyclic tensile behavior of steel-reinforced high strain-hardening ultrahigh-performance concrete (HSHUHPC) was investigated in this paper. In the experimental program, 12 HSHUHPC specimens concentrically placed in a single steel reinforcement under cyclic uniaxial tension were tested, accompanied by acoustic emission (AE) source locating technology, and 4 identical specimens under monotonic uniaxial tension were tested as references. The experimental variables mainly include the loading pattern, the diameter of the embedded steel rebar, and the level of target strain at each cycle. The tensile responses of the steel-reinforced HSHUHPC specimens were evaluated using multiple performance measures, including the failure pattern, load–strain response, residual strain, stiffness degradation, and the tension-stiffening behavior. The test results showed that the enhanced bond strength due to the inclusion of steel fibers transformed the failure pattern of the steel-reinforced HSHUHPC into a single, localized macro-crack in conjunction with a sprinkling of narrow and closely spaced micro-cracks, which intensified the strain concentration in the embedded steel rebar. Besides, it was observed that the larger the diameter of the embedded steel rebar, the smaller the maximum accumulative tensile strain under cyclic tension, which indicated that the larger the diameter of the embedded steel rebar, the greater the contribution to the tensile stiffness of steel-reinforced HSHUHPC specimens in the elastic–plastic stage. In addition, it was found that a larger embedded steel rebar appeared to reduce the tension-stiffening effect (peak tensile strength) of the HSHUHPC. Moreover, the residual strain and the stiffness of the steel-reinforced HSHUHPC were reduced by increasing the number of cycles and finally tended toward stability. Nevertheless, different target strain rates in each cycle resulted in different eventual cumulative tensile strain rates; hence the rules about failure pattern, residual strain, and loading stiffness were divergent. Finally, the relationship between the accumulative tensile strain and the loading stiffness degradation ratio under cyclic tension was proposed and the tension-stiffening effect was analyzed.     

A Flow Stress Model of the AA3104-H19 Alloy for the FEM Simulation of the Beverage Can Manufacturing Process under Large Plastic Deformations

This paper discusses the development of a flow stress model to simulate the AA3104-H19 alloy under the conditions of large plastic deformations characteristic of the beverage can manufacturing process. This study focuses on the first five steps of this process: cupping, redrawing, ironing #1, ironing #2, ironing #3. These are the stages that reduce the thickness of the base material to the maximum, resulting in an effective strain of more than 2.0, unattainable in conventional plastometric tests. To solve this problem, the specific calculation-experimental method for the development of the flow stress model was proposed. Based on the FEM modeling of the technological process, data on the history of deformation and the trajectory of movement of the selected points of the material at all stages of the production were obtained. Microspecimens for the tensile tests were taken from the points of the beverage can wall that were determined in this way. The initial strain of each sample was taken from the FEM simulation. In this way, the tensile curves were obtained for the material points at different stages of the production. The processing of these curves allowed the creation of a flow stress model for large strains, corresponding to production conditions. The tensile tests were performed on a Zwick Z250 machine at room temperature and strain rate of 0.005 s⁻¹. The FEM-based algorithm for the determination of empirical coefficients of the analytical flow stress model is presented. The final flow stress model covers the range of effective strain from 0–2. Validation of the developed model based on the measured beverage can thicknesses showed that a flow stress model was developed that correctly and accurately describes the forming process.     

Numerical and Experimental Investigations of Fracture Behaviour of Welded Joints with Multiple Defects

Current standards related to welded joint defects (EN ISO 5817) only consider individual cases (i.e., single defect in a welded joint). The question remains about the behaviour of a welded joint in the simultaneous presence of several different types of defects, so-called multiple defects, which is the topic of this research. The main focus is on defects most commonly encountered in practice, such as linear misalignments, undercuts, incomplete root penetration, and excess weld metal. The welding procedure used in this case was metal active gas welding, a common technique when it comes to welding low-alloy low-carbon steels, including those used for pressure equipment. Different combinations of these defects were deliberately made in welded plates and tested in a standard way on a tensile machine, along with numerical simulations using the finite element method (FEM), based on real geometries. The goal was to predict the behaviour in terms of stress concentrations caused by geometry and affected by multiple defects and material heterogeneity. Numerical and experimental results were in good agreement, but only after some modifications of numerical models. The obtained stress values in the models ranged from noticeably lower than the yield stress of the used materials to slightly higher than it, suggesting that some defect combinations resulted in plastic strain, whereas other models remained in the elastic area. The stress–strain diagram obtained for the first group (misalignment, undercut, and excess root penetration) shows significantly less plasticity. Its yield stress is very close to its ultimate tensile strength, which in turn is noticeably lower compared with the other three groups. This suggests that welded joints with misalignment and incomplete root penetration are indeed the weakest of the four groups either due to the combination of the present defects or perhaps because of an additional unseen internal defect. From the other three diagrams, it can be concluded that the test specimens show very similar behaviour with nearly identical ultimate tensile strengths and considerable plasticity. The diagrams shows the most prominent yielding, with an easily distinguishable difference between the elastic and plastic regions. The diagrams are the most similar, having the same strain of around 9% and with a less obvious yield stress limit.     

Fatigue Modeling and Numerical Analysis of Re-Filling Probe Hole of Friction Stir Spot Welded Joints in Aluminum Alloys

In the present study, the fatigue behavior and tensile strength of A6061-T4 aluminum alloy, joined by friction stir spot welding (FSSW), are numerically investigated. The 3D finite element model (FEM) is used to analyze the FSSW joint by means of Abaqus software. The tensile strength is determined for FSSW joints with both a probe hole and a refilled probe hole. In order to calculate the fatigue life of FSSW joints, the hysteresis loop is first determined, and then the plastic strain amplitude is calculated. Finally, by using the Coffin-Manson equation, fatigue life is predicted. The results were verified against available experimental data from other literature, and a good agreement was observed between the FEM results and experimental data. The results showed that the joint’s tensile strength without a probe hole (refilled hole) is higher than the joint with a probe hole. Therefore, re-filling the probe hole is an effective method for structures jointed by FSSW subjected to a static load. The fatigue strength of the joint with a re-filled probe hole was nearly the same as the structure with a probe hole at low applied loads. Additionally, at a high applied load, the fatigue strength of joints with a refilled probe hole was slightly lower than the joint with a probe hole.