Papers by Author: J. David Embury

Abstract: In this work we have outlined the use of micromechanical models which can rationalize the behaviour of a number of structural steels by including both static and dynamic length scales and considering the interaction of the phases. The approach treats the steels as composites but includes the influence of both volume fractions and physically based length scales and processes. In essence it can be extended to utilise the methodology outlined by Ashby&al. to include length scales in the development diagrams of composite materials.

Abstract: The application of 6000 series alloys is widespread and of particular importance to the automotive sector. Their functionality depends on the detailed behaviour of the strengthening phases. In this study, transmission electron microscopy (TEM) supplemented with a variety of mechanical tests were used to examine the precipitates and their role in aspects such as the Bauschinger effect, damage and fracture events, and in recovery and recrystallization processes.

Abstract: A number of mechanical tests and metallographic techniques have been used to investigate the mechanism of ductile fracture of AA5754 sheet. The sequence of events in the development of shear localization is clarified using in situ strain mapping on both the sample surface and through thickness direction during tensile tests. It is observed that the failure mode changes from cup-cone type to shearing with increasing Fe content in both continuous cast (CC) and direct-chill cast (DC) AA5754 sheets. However, this transition happens in CC with much lower Fe content than DC. As very little damage is found near the fracture surface, this suggests that damage may be a consequence of the shear process rather than a trigger that determines material ductility. For both CC and DC with same Fe content of 0.21%, fracture strain of CC is much lower than DC. It is postulated that this is due to the differences of particle distribution in these two materials, especially the increased fraction of stringer type structures which exist in CC material.

Abstract: This paper addresses the effect of microstructure on the formability of aluminium alloys of interest for automotive sheet applications. The bulk of this work has been on the alloy AA5754 – both conventional DC cast alloys and continuous cast alloys made by twin belt casting. It is known that alloys such as these contain Fe as a tramp impurity which results in Fe-based intermetallic particles distributed through microstructure as isolated particles and in stringers aligned along the rolling direction. It is thought that these particles are the cause, both of the reduced ductility that is observed as the Fe level rises, and the relatively poor formability of strip cast alloys, as compared with those made by DC cast. Conventional wisdom suggests that the reduction of ductility is due to the effect of particles as nucleating sites for damage. However, most studies show that these materials are resistant to damage until just before fracture. We now believe that effect is actually related to the development of shear bands in these materials. We present experimental data which supports this conclusion. We then show how the FE models we have developed demonstrate the role of shear instability on fracture and the role played by hard particles. We show how a unit cell approach can be used to incorporate the effect of particle density and morphology on shear localization in a way that includes statistical variability due to microstructural heterogeneity. This leads to a set of constitutive equations in which the parameters are distributed from one region to another. These are then fed into a macroscopic FE model at the level of the specimen or the component in order to determine the effect of microstructural variability on shear instability and ductility.

Abstract: The process of work hardening in aluminum alloys is important from the viewpoint of formability and the prediction of the properties of highly deformed products. However the complexity of the strengthening mechanisms in these materials means that one must carefully consider the interaction of dislocations with the detailed elements of the microstructure and the related influence of the elements on dislocation accumulation and dynamic recovery. In addition, it is necessary to consider the influence of the work hardening process at various levels of plastic strain. This permits the possibility of designing microstructure for tailored plastic response, e.g. not simply designed for yield strength but also considering uniform elongation, spring-back, ductility etc. This presentation will explore the concept of identifying the various interactions which govern the evolution of the work hardening and their possible role in alloy design.