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Alloy design for mechanical properties: Conquering the length scales

Published online by Cambridge University Press:  09 April 2019

Irene J. Beyerlein
Affiliation:
Department of Mechanical Engineering, Materials Department, University of California, Santa Barbara, USA; beyerlein@ucsb.edu
Shuozhi Xu
Affiliation:
California NanoSystems Institute, University of California, Santa Barbara, USA; shuozhixu@ucsb.edu
Javier Llorca
Affiliation:
IMDEA Materials Institute, and Department of Materials Science, Polytechnic University of Madrid, Spain; javier.llorca@imdea.org
Jaafar A. El-Awady
Affiliation:
Department of Mechanical Engineering, Whiting School of Engineering, Johns Hopkins University, USA; jelawady@jhu.edu
Jaber R. Mianroodi
Affiliation:
Microstructure Physics and Alloy Design, Max-Planck-Institut für Eisenforschung GmbH; and Material Mechanics, RWTH Aachen University, Germany; j.mianroodi@mpie.de
Bob Svendsen
Affiliation:
Microstructure Physics and Alloy Design, Max-Planck-Institut für Eisenforschung GmbH; and Material Mechanics, RWTH Aachen University, Germany; b.svensden@mpie.de

Abstract

Predicting the structural response of advanced multiphase alloys and understanding the underlying microscopic mechanisms that are responsible for it are two critically important roles that modeling plays in alloy development. The demonstration of superior properties of an alloy, such as high strength, creep resistance, high ductility, and fracture toughness, is not sufficient to secure its use in widespread applications. Still, a good model is needed to take measurable alloy properties, such as microstructure and chemical composition, and forecast how the alloy will perform in specified mechanical deformation conditions, including temperature, time, and rate. Here, we highlight recent achievements using multiscale modeling in elucidating the coupled effects of alloying, microstructure, and mechanism dynamics on the mechanical properties of polycrystalline alloys. Much of the understanding gained by these efforts relies on the integration of computational tools that vary over many length scales and time scales, from first-principles density functional theory, atomistic simulation methods, dislocation and defect theory, micromechanics, phase-field modeling, single crystal plasticity, and polycrystalline plasticity.

Information

Type
Computational Design And Development Of Alloys
Copyright
Copyright © Materials Research Society 2019 
Figure 0

Figure 1. Current view of the state of multiscale materials modeling (MMM) on the mesoscale. Note: FFT, fast Fourier transform.

Figure 1

Figure 2. Final precipitate size and morphologies predicted from multiscale simulations elucidating the differences that can be expected in high-temperature precipitate homogeneous and heterogeneous nucleation, and growth in Al-Cu alloys. Note: circled numbers, precipitate variants; b, Burgers vector.8

Figure 2

Figure 3. (a–c) Shear of ${\rm{\gamma '}}$ precipitate by Co decorated $\left\langle {110} \right\rangle /2$ edge dislocation in the ${\rm{\gamma }}$ phase. Dark blue and dark red represent 3.2 and 6.0 at.% Co, respectively. All faults are separated by partial dislocations. The scale is the same in (a–c). (d) Fault energy results for a dissociated $\left\langle {110} \right\rangle /2$ dislocation in Ni3Al-Co (red curve). The segregated Co concentration profile is shown in blue. Results in (a–c) are for a moving dislocation, and those in (d) for a static dislocation.20 Note: CSF, complex stacking fault; APB, antiphase boundary.

Figure 3

Figure 4. The effect of precipitate size, r, on the (a) engineering stress–strain response; and (b) dislocation density versus engineering strain, for freestanding single-crystal Ni-based superalloy microcrystals. The simulation cell volume was fixed at 1 × 1 × 3 μm3, the precipitates were cuboidal with a volume fraction of 0.7, and the antiphase boundary energy was 0.2 J/m2. The precipitate distribution and the dislocation network at the onset of the plastic flow are shown in (b, c) for r = 0.2 μm and 0.5 μm, respectively. The dislocation lines in (b, c) are colored according to their slip system.27

Figure 4

Figure 5. (a) Effect of alloying addition on tension-compression (T–C) yield stress ratio for magnesium alloys. Magnesium alloys with different alloying elements are characterized by the plastic anisotropic (PA) measure. (b, c) Polycrystal yield surface (π-plane projection) for different magnesium alloys at 3% compressive strain along the rolling direction.37 (b) The Mg4Li alloy has one of the smallest PA measures, showing low tension-compression yield stress asymmetry; (c) the ZW41 alloy has the largest PA measure and concomitantly large tension-compression asymmetry.

Figure 5

Figure 6. Schematic representation of multiple scales in the development of a crystal plasticity finite element (CPFE) model for Ni-based superalloys. (a) Polycrystalline microstructure showing the finite element mesh, (b) subgrain microstructure in a single grain, (c) discretized subgrain microstructural representative volume element, and (d) homogenized CPFE model for a grain. Note: lG, grain size; lP and lS, model constants. Reprinted with permission from Reference 46. © 2015 Elsevier.

Figure 6

Figure 7. Variation of the driving force for twin transmission across a grain boundary with the misorientation of the grain boundary for two Mg alloys (a) AZ31 and (b) Mg4Li. A value of unity implies that the driving force for twinning in the neighboring grain at the tip of the twin is equal to that for twin propagation of the same twin in its parent crystal. A high (or too high) misorientation regime is well marked by a cutoff misorientation angle Δθcut, above which the chances for twin transmission are zero. (c) Map of the variation of cutoff angles for a wide range of alloys. Alloys are indicated by their plastic anisotropic (PA) measure in Equation 1. An arbitrarily defined practical cutoff angle, associated with a driving force ratio of 0.5 is also marked. This angle corresponds to a neighboring grain that bears a driving force that is 50% lower than that to propagate a twin in its own parent crystal. These more practical cutoff angles follow the same variation with PA as seen in (c). However, this 50% chance misorientation angle is more likely to be consistent with experimental observation. It is reasonable to expect that twin transmission would rarely be seen, particularly when the data sets are small, for misorientations corresponding to this practical cutoff angle, which is ∼36° for the low PA alloys and ∼50° for the highest one.60