Overview of constitutive laws, kinematics, homogenization and multiscale methods in crystal plasticity finite-element modeling: Theory, experiments, applications

Friction stir welding (FSW), a new welding technique invented at TWI, was used to weld 7075 T651 aluminum, an alloy considered essentially unweldable by fusion processes. This weld process exposed the alloy to a short time, high-temperature spike, while introducing extensive localized deformation. Studies were performed on these solid-state welds to determine mechanical properties both in the longitudinal direction, i.e., within the weld nugget, and, more conventionally, transverse to the weld direction. Because of the unique weld procedure, a fully recrystallized fine grain weld nugget was developed. In addition, proximate to the nugget, both a thermomechanically affected zone (TMAZ) and heat affected zone (HAZ) were created. During welding, temperatures remained below the melting point and, as such, no cast or resolidification microstructure was developed. However, within the weld nugget, a banded microstructure that influences room-temperature fracture behavior was created. In the as-welded condition, weld nugget strength decreased, while ductility remained high. A low-temperature aging treatment failed to fully restore T651 strength and significantly reduced tensile ductility. Samples tested transverse to the weld direction failed in the HAZ, where coarsened precipitates caused localized softening. Subsequent low-temperature aging further reduced average strain to failure without affecting strength. Although reductions in strength and ductility were observed, in comparison to other weld processes, FSW offers considerable potential for welding 7075 T651 aluminum.

Properties of friction-stir-welded 7075 T651 aluminum

Crack tip shielding phenomena, whereby the “effective crack-driving force” actually experienced at the crack tip is locally reduced, are examined with reference to fatigue crack propagation behavior in metals, composites and ceramics. Sources of shielding are briefly described in terms of mechanisms relying on the production of elastically constrained zones which envelop the crack (zone shielding), on the generation of wedging, bridging or sliding forces between the crack surfaces (contact shielding) and on crack path deflection and meandering. Examples are taken from the fatigue behavior of high strength lithium-containing aluminum alloys, aluminum alloy-aramid fiber-epoxy laminate composites, and zirconia ceramics. It is shown that, whereas crack tip shielding can provide a potent means of enhancing “resistance” to crack growth, such extrinsic toughening mechanisms can result in the apparently anomalous behavior of “small cracks” and to the susceptibility of brittle materials to fatigue failure.

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Mechanisms of fatigue crack propagation in metals, ceramics and composites: Role of crack tip shielding☆

A technical review of the physical, mechanical, and metallurgical variables that have influenced performance of Al-Li based alloys over the last 50 years is presented. First, the historic evolution of different alloys is discussed. Then, the microstructural features responsible for different mechanical properties are identified and discussed. The role of alloying additions is discussed. The shortcomings of a 2nd generation Al-Li alloys are introduced and the key alloy design principles used to overcome these are discussed. Finally, the performance parameters that play a major role in sizing several aircraft and space craft components are reviewed in a chronological perspective and compared with 3rd-generation Al–Li alloys. It is concluded that significant improvements have been made to position Al–Li alloys to enable improved performance of next generation of air and space craft.

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The Evolution of Al-Li Base Products for Aerospace and Space Applications

Aluminum alloy 7050 was friction-stir welded (FSW) in a T7451 temper to investigate the effects on the microstructure and mechanical properties. Results are discussed for the as-welded condition (as-FSW) and for a postweld heat-treated condition consisting of 121 °C for 24 hours (as-FSW + T6). Optical microscopy and transmission electron microscopy (TEM) examination of the weld-nugget region show that the FS welding process transforms the initial millimeter-sized pancake-shaped grains in the parent material to fine 1 to 5 µm dynamically recrystallized grains; also, the FS welding process redissolves the strengthening precipitates in the weld-nugget region. In the heat-affected zone (HAZ), the initial grain size is retained, while the size of the strengthening precipitates and of the precipitatefree zone (PFZ) is coarsened by a factor of 5. Tensile specimens tested transverse to the weld show that there is a 25 to 30 pct reduction in the strength level, a 60 pct reduction in the elongation in the as-FSW condition, and that the fracture path is in the HAZ. The postweld heat treatment of 121 °C for 24 hours did not result in an improvement either in the strength or the ductility of the welded material. Comparison of fatigue-crack growth rates (FCGRs) between the parent T7451 material and the as-FSW + T6 condition, at a stress ratio of R = 0.33, shows that the FCG resistance of the weldnugget region is decreased, while the FCG resistance of the HAZ is increased. Differences in FCGRs, however, are substantially reduced at a stress ratio of R = 0.70. Analysis of residual stresses, fatigue-crack closure, and fatigue fracture surfaces suggests that decrease in fatigue crack growth resistance in the weld-nugget region is due to an intergranular failure mechanism; in the HAZ region, residual stresses are more dominant than the microstructure improving the fatigue crack growth resistance.

Friction-stir welding effects on microstructure and fatigue of aluminum alloy 7050-T7451

Grain boundary ductile fracture in precipitation hardened aluminum alloys

The role of microstructure and environment in influencing ultra-low fatigue crack propagation rates has been investigated in 7075 aluminum alloy heat-treated to underaged, peak-aged, and overaged conditions and tested over a range of load ratios. Threshold stress intensity range, ΔK0, values were found to decrease monotonically with increasing load ratio for all three heat treatments fatigue tested in 95 pct relative humidity air, with ΔK
 0 decreasing at all load ratios with increased extent of aging. Comparison of the near-threshold fatigue behavior obtained in humid air with the data forvacuo, however, showed that the presence of moisture leads to a larger reduction in ΔK0 for the underaged microstructure than the overaged condition, at all load ratios. An examination of the nature of crack morphology and scanning Auger/SIMS analyses of near-threshold fracture surfaces revealed that although the crack path in the underaged structure was highly serrated and nonlinear, crack face oxidation products were much thicker in the overaged condition. The apparent differences in slow fatigue crack growth resistance of the three aging conditions are ascribed to a complex interaction among three mechanisms: the embrittling effect of moisture resulting in conventional corrosion fatigue processes, the role of microstructure and slip mode in inducing crack deflection, and crack closure arising from a combination of environmental and microstructural contributions.

Mechanisms of Slow Fatigue Crack Growth in High Strength Aluminum Alloys: Role of Microstructure and Environment

Microscopic and macroscopic aspects of fracture in lithium-containing aluminum alloys

The role of corrosion deposits in influencing the near-threshold fatigue crack propagation behavior of 2XXX and 7XXX series aluminum alloys is examined in detail. The composition, thickness, and distribution of fracture surface oxide films are characterized with the aid of X-ray photoelectron spectroscopy, scanning Auger spectroscopy, and secondary ion mass spectroscopy analyses. It is found that the extent of crack closure due to corrosion debris in aluminum alloys is strongly dependent on the composition and aging treatment. The results suggest that environmentally-influenced near-threshold crack propagation in some aluminum alloys is controlled by twoconcurrent andmutually-compctitive mechanistic processes: a dominant role of crack closure due to corrosion deposits (which tends toarrest completely the near-threshold crack) and a strong embrittling effect (which considerablyincreases near-threshold crack growth rates) concomitantly with the crack tip oxidation phenomenon in the moist medium. The near-threshold corrosion fatigue characteristics of aluminum alloys are contrasted with those in a wide range of steels in order to gain an insight into the various

A. K. Vasudévan

Papers

Grain boundary ductile fracture in precipitation hardened aluminum alloys

Mechanisms of Slow Fatigue Crack Growth in High Strength Aluminum Alloys: Role of Microstructure and Environment

Microscopic and macroscopic aspects of fracture in lithium-containing aluminum alloys

Influence of corrosion deposits on near-threshold fatigue crack growth behavior in 2xxx and 7xxx series aluminum alloys

An analysis of ductile failure by grain boundary void growth