Finite Element Simulations of Crack Propagation in Al2O3/6061Al Composites

doi:10.1007/s40195-014-0124-5

Abstract

Abstract:

In this work, the local fracture initiation behaviour of an Al₂O₃/6061Al composite is studied numerically. The damage behaviour of the microstructure is evaluated in consideration of the path and the amount of damage as well as the stress-strain performance of the microstructure. The damage behaviour of the ductile matrix has been simulated using the damage parameter D. For the simulation of fracture of the ceramic particles, a normal stress criterion is applied. For the analysis of the damage behaviour of the transition zone between particulate and matrix, both damage models (D parameter and normal stress criteria) are applied in this region. Parameter studies of crack propagation prediction in the Al₂O₃/6061Al composite on the basis of an Element Elimination technique have been performed for two differently heat-treated variants resulting in different mechanical properties. In addition, residual stress effects on the damage behaviour are examined for various microstructural situations.

Key words: Metal matrix composites, Simulation, Crack propagation, Finite element method, Element elimination technique

Lasko Galina, Weber Ulrich, Schmauder Siegfried. Finite Element Simulations of Crack Propagation in Al₂O₃/6061Al Composites[J]. Acta Metallurgica Sinica (English Letters), 2014, 27(5): 853-861.

Figures/Tables 13

Table 1 Elastic properties and thermal expansion coefficient used in the FE simulations

Material	Elastic modulus, E (MPa)	Poisson´s ratio, ν	Thermal expansion coefficient, α (10⁻⁶/K)
6061Al matrix	66,000	0.33	23.87
Al₂O₃ particles	380,000	0.22	2.60

Fig. 1 Stress-strain curves for the 6061Al-T6 matrix, ductile transition phase and brittle Al2O3 inclusion. The elastic-plastic stress-strain curves are used alternatively for both Al-matrix and interface

Table 2 Variations of mechanical properties and damage parameters of MMC constituents used in different simulations

Simulation	Properties of the transition phase	Damage criteria			Residual stress
Simulation	Properties of the transition phase	Transition phase	Matrix	Particles	Residual stress
No. 1	Brittle, E = 326 GPa, ν = 0.3	Normal stress, σ _c = 4,000 MPa	Rice and Tracey, A = 2.82 B = 2.07 D _c = 1	Normal stress, σ _c = 3,000 MPa	Yes (cooling down from 500°C till 20°C)
No. 2					No
No. 3	Without transition phase	The same criterion as for particle	Rice and Tracey, A = 2.82, B = 2.07, D _c = 1	σ _c = 3,000 MPa σ _c = 1,500 MPa	Yes
No. 4	Brittle, E = 326 GPa, ν = 0.3	Normal stress, σ _c = 3,000 MPa	Rice and Tracey, A = 2.82, B = 2.07, D _c = 1	Normal stress, σ _c = 4,000 MPa	Yes
No. 5	Ductile, harder than matrix	Rice and Tracey, A = 1.41 B = 1.035 D _c = 1	Rice and Tracey, A = 2.82, B = 2.07, D _c = 1	Normal stress, σ_crit = 4,000 MPa	Yes
No. 6	Ductile, harder than matrix	Rice and Tracey, A = 1.41 B = 1.035 D _c = 1	Rice and Tracey, A = 2.82, B = 2.07, D _c = 1	Normal stress, σ_crit = 4,000 MPa	No
No. 7	Ductile, softer than matrix	Rice and Tracey, A = 2.82 B = 2.07 D _c = 1	Rice and Tracey, A = 1.41, B = 1.035, D _c = 1	Normal stress, σ _c = 4,000 MPa	Yes
No. 8	Ductile, softer than matrix	Rice and Tracey, A = 2.82 B = 2.07 D _c = 1	Rice and Tracey, A = 1.41, B = 1.035, D _c = 1	Normal stress, σ _c = 4,000 MPa	No

Fig. 2 Boundary conditions and FE-mesh of cut-out of Al2O3/6061Al MMC (white represents inclusion, green represents the matrix and dark green represents the transition phase)

Fig. 3 Stress-strain curves for the cut-out of the microstructure from Fig. 2 with different properties of the transition phase: a without residual stresses; b with residual stresses

Fig. 4 Damage evolution in Al2O3/6061Al composite microstructure obtained by simulation No. 1 at the following deformation steps: a strain is 0.5%; b strain is 1.1%; c strain is 2.0%; d strain is 2.8%; e strain is 3.8%; f strain is 4.5%

Fig. 5 Damage evolution in the model of the Al2O3/6061Al composite microstructure obtained by simulation No. 1 at the following macroscopic deformation steps: a strain is 0.5%; b strain is 2.0%; c strain is 3.8%; d strain is 4.5%

Fig. 6 Stress-strain curves for the small cut-out from the microstructure of the specimen under tensile loading with accounting of residual stresses with different values of critical normal stress damage criterion for inclusion (simulation No. 3 in Table 2)

Fig. 7 Damage evolution in the model of the Al2O3/6061Al composite microstructure obtained by simulation No. 4 at the following macroscopic deformation steps: a strain is 0.5%; b strain is 2.0%; c strain is 3.8%; d strain is 4.5%

Fig. 8 Damage evolution in the model of the Al2O3/6061Al composite microstructure obtained by simulation No. 5 at the following macroscopic deformation steps: a strain is 0.5%; b strain is 2.0%; c strain is 2.8%; d strain is 4.5%

Fig. 9 Damage evolution in the model of the Al2O3/6061Al composite microstructure obtained by simulation No. 7 at the following macroscopic deformation steps: a strain is 0.5%; b strain is 1.1%; c strain is 2.0%; d strain is 2.8%

Fig. 10 Stress-strain curve for the microscopic cut-out of the microstructure from Fig. 2 under tensile loading after cooling down from 500 to 200 and 100°C, respectively

Fig. 11 Stress-strain curve for the microscopic cut-out of the microstructure from Fig. 2 under tensile loading after cooling down from 500, 200 and 100°C to room temperature

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Finite Element Simulations of Crack Propagation in Al₂O₃/6061Al Composites

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