Vladimir Kostov

Bio: Vladimir Kostov is an academic researcher from Karlsruhe Institute of Technology. The author has contributed to research in topics: Residual stress & Stress (mechanics). The author has an hindex of 6, co-authored 10 publications receiving 122 citations.

Internal load transfer and damage evolution in a 3D interpenetrating metal/ceramic composite

Abstract: The internal load transfer and compressive damage evolution in an interpenetrating Al 2 O 3 /AlSi12 composite have been studied in this work. The composite was fabricated by squeeze-casting eutectic aluminium–silicon alloy melt in a porous alumina preform. The preform was fabricated from a mixture of cellulose fibres and alumina particles via cold pressing and sintering. In an earlier work we reported the internal load transfer in the same composite material under monotonic compression and tension studied using energy dispersive synchrotron X-ray diffraction [20] . The current work is a continuation of this earlier study, aimed at obtaining further understanding about load transfer occurring during load reversal and damage behaviour during external compression. The micromechanical load partitioning between the three phases present in the composite is studied during one load cycle starting in compression followed by unloading and reloading in tension until failure. Average strain and stress value in each phase is calculated from several diffraction planes of each phase and as a result the reported strain and stress are representative of the bulk material behaviour. The load transfer results allow identifying the occurrence of a substantial Bauschinger effect in the Al solid solution phase and progressive damage evolution within the alumina phase. In situ compression test inside a scanning electron microscope showed that failure of the composite occurred by propagation of cracks through the ceramic rich regions, oriented at approximately 45° to the loading direction.

Fast in situ phase and stress analysis during laser surface treatment: a synchrotron x-ray diffraction approach.

Abstract: An in situ stress analysis by means of synchrotron x-ray diffraction was carried out during laser surface hardening of steel. A single exposure set-up that based on a special arrangement of two fast silicon strip line detectors was established, allowing for fast stress analysis according to the sin2ψ x-ray analysis method. For the in situ experiments a process chamber was designed and manufactured, which is described in detail. First measurements were carried out at the HZG undulator imaging beamline (IBL, beamline P05) at the synchrotron storage ring PETRA III, DESY, Hamburg (Germany). The laser processing was carried out using a 6 kW high power diode laser system. Two different laser optics were compared, a Gaussian optic with a focus spot of o 3 mm and a homogenizing optic with a rectangular spot dimension of 8 × 8 mm2. The laser processing was carried out using spot hardening at a heating-/cooling rate of 1000 K/s and was controlled via pyrometric temperature measurement using a control temperature of 1150 °C. The set-up being established during the measuring campaign allowed for this first realization data collection rates of 10Hz. The data evaluation procedure applied enables the separation of thermal from elastic strains and gains unprecedented insight into the laser hardening process.

Local Residual Stress Distributions Induced by Repeated Austenite-Martensite Transformation via Laser Surface Hardening of Steel AISI 4140

Abstract: The effects of laser surface hardening of steel samples on the microstructure and residual stresses were determined for single as well as multiple laser pulses. Samples made of steel grade AISI 4140 were hardened by means of a high-power diode laser (HPDL) system using either single or multiple laser pulses resulting in single as well as repeated austenite-martensite transformations. The hardening was carried out in a specially designed process chamber allowing laser surface treatment in inert atmosphere in order to avoid oxide scale formation. The residual stress distributions in lateral and in depth direction were analysed by means of X-ray diffraction for samples hardened by up to 27 laser pulses. Residual stress analyses were carried out by means of the sin²y - method. The results indicate the extension of the hardened zone in lateral and in depth direction with an increase in the number of applied laser pulses. This evolution is connected with significant changes in the local residual stress distributions.

Linking process, structure, property, and performance for metal-based additive manufacturing: computational approaches with experimental support

Abstract: Additive manufacturing (AM) methods for rapid prototyping of 3D materials (3D printing) have become increasingly popular with a particular recent emphasis on those methods used for metallic materials. These processes typically involve an accumulation of cyclic phase changes. The widespread interest in these methods is largely stimulated by their unique ability to create components of considerable complexity. However, modeling such processes is exceedingly difficult due to the highly localized and drastic material evolution that often occurs over the course of the manufacture time of each component. Final product characterization and validation are currently driven primarily by experimental means as a result of the lack of robust modeling procedures. In the present work, the authors discuss primary detrimental hurdles that have plagued effective modeling of AM methods for metallic materials while also providing logical speculation into preferable research directions for overcoming these hurdles. The primary focus of this work encompasses the specific areas of high-performance computing, multiscale modeling, materials characterization, process modeling, experimentation, and validation for final product performance of additively manufactured metallic components.