Multi-scale analysis based study of effect of micro-level damage on macro-level thermo-mechanical response of ductile material

Sriram Ganesan , Dr. C.S. Upadhyay

Department of Aerospace Engineering, IIT Kanpur, Kanpur-208 016

Abstract
Constitutive descriptions for deterioration of material strength capacity due to separation or rupture of material have been the focus of numerous investigations in the field of continuum damage mechanics. Presently, empirical scalar-based damage descriptions are used in practical numerical simulations of impact and failure. For ductile metals, the model introduces a damage parameterthe cumulative scalar plastic strain at failure whose instantaneous value may depend upon the strain rate, temperature, deviatoric stress, and/or hydrostatic pressure. The broader aim of the investigation is to develop a framework for describing the deformation and failure responses of ductile materials from micromechanical considerations and volume averaging techniques in a computationally efficient way and for a broad range of load conditions. Two dimensional micromechanical model based simulations were conducted to study influence of interacting flows. Also the microscopic structure of 9 Cr-1 Mo Steel, which is being used in Nuclear applications was studied both in undamaged and damaged state.

Undamaged Sample before Etching

Material models for porous materials

Micromechanically based models are based on the physical understanding that in the course of plastic deformation, microvoids nucleate and grow until a localised plastic necking or fracture of the inter-void matrix occurs, which causes coalescing of neighboring voids. The model was proposed by Gurson [3] and phenomenologically extended by Tvergaard and Needleman[4] called the GTN model. An approach based on continuum damage mechanics(CDM) and thermodynamics has been proposed by Rousselier [5]. The plastic flow potential is written as

.9 Comparison of Gurson and Rousselier Models

Fig 2 a,b) Undamaged unetched sample c) Alumina Impurities

Tensile Testing of the sample

The Sample was damaged by conducting a Tensile Testing in a 20 ton Universal Testing Machine Testing Parameters: Specimen Type: Flat Test Mode : Stroke ( Displacement Controlled) Gauge Length : 30mm Displacement Rate : 1mm/min Cross Sectional Area of Sample : 58.5239 sq-mm Peak Stress : 404.1 kN/sq-mm Yield Point Load: 23.1551kN
0.450 0.400 0.350

Where R is the yield stress of undamaged material(matrix) p is an effective plastic strain representative of matrix hardening, * is an effective scalar stress which is a function of both macroscopic stress tensor and porosity. * is defined by the following equations: Gurson Model:

Fig 5 : Yield Surfaces for Gurson and Rousselier Model Fig compares both the yield surfaces in eq-kk plane in the case of tensile stress (kk >0). Under pure shear (kk =0), damage is still generated in the case of Rousselier model ( as the normal to the yield surface does not coincide with the axis), whereas in the absence of nucleation, the Gurson model does not lead to damage growth.

Modelling porous plasticity using Simulia Abaqus 6.9

Rousselier Model:

Elastic Model:

Stress, kN/sq-mm

Microstructure of 9 Cr-1Mo Steel

Cr-Mo ferritic steels are widely used as the structural material of the steam pipes in fossil and nuclear power plants because of their excellent strength as well as their good oxidation resistance at a high temperature. The mechanical strength of 9Cr-1Mo steel at an elevated temperature can be improved by V and Nb additions and it is called a modified 9Cr-1Mo steel. Modified 9Cr-1Mo steel is being considered as a structural material for the reactor pressure vessel and piping in advanced reactors such as VHTR(Very High Temperature Reactor) and SFR(Sodium Fast Reactor). The interest on the weld characteristics of modified 9Cr-1Mo steel is increasing due to its potentiality for application in all modern power plants and advanced reactor system[1]

0.300 0.250 0.200 0.150 0.100 0.050 0.000 0.000 0.001 0.002 0.003 0.004 0.005 Strain 0.006 0.007 0.008 0.009

Where is the von Mises equivalent stress and kk is the trace(tr) of the stress tensor. q1, q2, q3,D and are material coefficients which are assumed to be constant. f* is a function of the porosity f which was introduced on a purely phenomenological basis to represent void coalescence. ([4]). Deformation Rule: Obtained assuming normality rule

Fig 6 a) Loading b) Stress Distribution c) Inclusion

Porous Plasticity model:

Fig 2 a) Stress Strain Curve b) Universal Testing Machine

Damaged Sample Microstructure

Where v_ is the normal to the flow potential. Total strain is expressed as e+ p, where p is the elastic strain rate.

Fig 7 a) Loading b) Stress Distribution c) Interference of Voids

Discussion and Further Scope

Porous Plasticity could not be incorporated into Plane Stress model and so the material under elastic regime is shown in Fig 6. A separate extruded 3-d model having two interfering voids is modelled and analysed as shown in Fig 7. The model can be expanded to include process inducedr esidual stresses, vector damage potential and micromechanics based evolution laws.

Properties of 9Cr- 1Mo Steel

Chemical composition in weight %: 0.10% C, 0.49% Si, 0.46% Mn, 0.085% P, 8.36% Cr, 0.97% Mo.

Fig 3 a,b,c) Damaged Unetched Sample

In case of Gurson model

Fig 4 a,b) Damaged Etched sample c) 9Cr-1Mo Steel [2]

Youngs modulus:

200GPa 0.3
1.2105 per C

Work hardening rate Specific heat

300MPa
586 J/(kgC)

Observations and Conclusions

Size of original Size it a be on the Poster Since etching was not done, willsecondary cleaning with an ultrasonic cleaner and an appropriate surfactant as acetone was done for removing inaccessible alumina located in specimen cracks or pores (Fig. 1c). Since the specimen was small tensile testing could not be carried out in accordance with ASTM specifications. The inclusions seen are the M23C6 precipitates. The crevices seen in the surface are due to a combination of voids and polishing defects.

In case of Rousselier Model Where e. is the deviator of the strain rate tensor. In this case p. corresponds to the von Mises equivalent strain rate. p. can be computed writing the consistency condition .=0 in case of plasticity. Evolution of the porosity is given by mass conservation modified to account for strain controlled void nucleation.[6]

Acknowledgements
I would like to sincerely thank Prof. Sandeep Sangal, MME Department, for the invaluable suggestions and inputs he had given me on Metallography. I would also like to sincerely thank Mr. Jitender, Mr. Hari Om Bajpai, Mr. Pravin Kumar Sharma, Mr. Nitin Awasthi, Mr. Shishir Pandya and Ms. Aparna Mitra for their help during the entire duration of the project.

Poissons Ratio
Thermal expansion coefficient Initial static yield stress

Conductivity

52 J/(m-s-C)

References
[1] 1. A. Barnes, The Influence of Composition on Microstructural Development and Toughness of Modified 9%Cr-1%Mo Weld Metals, Report 509/1995, TWI, Abington, UK, 1995 [2] B. Arivazhagan, Ranganath Prabhu, S.K. Albert, M. Kamaraj, and S. SundaresanMicrostructure and Mechanical Properties of 9Cr-1Mo Steel Weld Fusion Zones as a Function of Weld Metal Composition [3]Gurson.A ,1977. Continuum theory of ductile rupture by void nucleation and growth. Part-I Yield Criteria and flow rules for porous ductile media. J. EnggMatter Tech. 99,2-15 [4]Tvergaard V, Needleman A, 1984. Analysis of cup cone fracture in a round tensile bar. Acta Metall157-69 [5]Rousselier G,1987, Ductile fracture models and their potential in local approach of fracture. Nuclaer engg Des. 105, 97-111 [6]Chu C, Nedleman 1980 Void nucleation effects in biaxially stretched sheets, J. Engg Matter102,249-256
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700MPa

Initial relative density

0.95 ( 0.05)

Table 1 Physical and Mechanical Properties of 9Cr-1Mo Steel