In situ time of flight neutron diffraction and X-ray synchrotron diffraction methods were applied to measure lattice strains in duplex steels during a tensile test. The experimental results were used to study slips on crystallographic planes and the mechanical effects of damage occurring during plastic deformation. For this purpose the prediction of an elastoplastic self-consistent model was compared with the experimental data. The used methodology allowed to determine the elastic limits and parameters describing work hardening in both phases of studied polycrystalline materials. In the second part of this work the developed elastoplastic model was applied to study damage occurring in the ferritic phase. The theoretical results showed a significant reduction of stresses localized in the damaged phase (ferrite) and confirmed the evolution of the lattice strains measured in the ferritic and austenitic phases.
The aim of the investigations was to determine the effect of parameters of refill friction stir spot welding (RFSSW) on the fracture load and failure mechanisms of the resulting joint. RFSSW joints were made in 7075-T6 Alclad aluminium alloy sheets using different welding parameters. The load capacity of joints was determined under tensile/shear loadings. Finite element-based numerical simulations of the joint-loading process were carried out, taking into account the variability of elasto-plastic properties of weld material through the joint cross-section. The influence of welding parameters on selected phenomena occurring during the destruction of the joint is presented. The considerations were supported by a fractographic analysis based on SEM images of fractures. It was found that there is a certain optimal amount of heat generated, which is necessary to produce the correct joint in terms of its load capacity. This value should not be exceeded, because it leads to weakening of the base material and thus to a reduction in the strength of the joint. Samples subjected to uniaxial tensile shear load showed three types of failure mode (tensile fracture, shear fracture, plug type fracture) depending on the tool rotational speed and duration of welding. Prediction of the fracture mode using FE-based numerical modelling was consistent with the experimental results. The samples that were damaged due to the tensile fracture of the lower sheet revealed a load capacity (LC) of 5.76 KN. The average value of LC for the shear fracture failure mechanism was 5.24 kN. The average value of the LC for plug-type fracture mode was 5.02 kN. It was found that there is an optimal amount of heat generated, which is necessary to produce the correct joint in terms of its LC. Excessive overheating of the joint leads to a weakening of the base metal and thus a reduction in the strength of the joint. Measurements of residual stresses along the axis specimens showed the presence of stresses with a certain constant value for the welded area on the side of the 1.6 mm thick plate.
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