| Artículo 4 | |
DEVELOPMENT OF WIRE DRAWING TEXTURES IN Cu-Fe. THE INFLUENCE OF MACROSCOPIC AND MICROSCOPIC HETEROGENEITIES
R.E. Bolmaro1, A. Fourty1, J. W. Signorelli1 and H.-G. Brokmeier2
1 Instituto de Física Rosario - Fac. de Ciencias Exactas, Ingeniería y Agrimensura. Consejo Nacional de Investigaciones Científicas y Técnicas, Bv. 27 de febrero 210 bis, 2000, Rosario, Argentina. bolmaro@ifir.ifir.edu.ar
2 Institut für Werkstoffkunde und -technik der Technische Universität Clausthal. GKSS Forschungszentrum Geesthacht, Max Planck Str. Geb 03, 21502 Geesthacht, Germany
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Introduction The main purpose of texture simulation is the reliable understanding and prediction of textures. A good understanding of the main underlying mechanisms for the presence of different components has been achieved but the models have not been so successful in the prediction of texture sharpness or component intensities. It is quite well understood that slight differences in strain rates, grain size and/or alloying compositions, through stacking fault energy changes, can influence the rate of development and the final sharpness of textures. However a more general disagreement between simulations and experiments is the evident lack of sharpness matching by, sometimes, an order of magnitude at high deformations. While component texture prediction and sharpness matching is quite good at medium strains the simulations do not do so well at very low and high deformations. The main argued reason for that disagreement is a well accepted one: Each grain does not follow exactly the equal deformation Taylor assumption neither follows some of the Self-Consistent model calculations. The technical procedure has long been an appropriate Gaussian smoothing, capable to reduce the intensities to levels compatible with experiments. However minor components are usually not attainable by such procedure.
Experimental data The experimental data consists in texture measurements performed in extrusion-wire drawing of Cu-Fe powder composites. The starting samples are 25%Cu-75%Fe hot extruded samples prepared by powder metallurgy (800 oC). The samples were afterwards wire drawn to a Von Mises strain of 3.0 at room temperature. The starting texture and the texture every 0.25 Von Mises strain for both phases were measured by neutron diffraction using the TEX-2 diffractometer [8] at the Geesthacht Neutron Facility (GeNF), Germany. Experimental information was processed by using software packages supported in popLA [9] and Beartex [10]. The same packages are later on used for processing the simulation results ensuring a similar transfer function. That is to say, the Euler angles orientation-weight files used for simulations and the orientation-intensity files used for ODF plotting are smoothed only by the numerical procedure used to process the experimental data. A 5º x 5º grid is used for both experiments and simulations. Details about sample fabrication and measurement procedure have been provided elsewhere [11]. Fig. 3 g) shows the inverse pole figures for an equivalent strain of 3.0. Three main components are noticeable at almost the same level of strength for Cu: Preferential <100>, <111> and <112> orientations along the cylindrical axes of the sample with a low sharpness. Fe shows the characteristic <110> orientation, along the same sample direction, with an incomplete fiber or spread to the <113> direction with a minor intermediate maximum. The
crystal behavior follows a potential law relating the applied stress
(1)
where
The
material behavior under a viscoplastic regime is described through the following
expression:
where
where
where
where
where
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![]() Fig. 1. Power law relationships between average misorientation angle and equivalent deformation. Hughes et al. experiments [17]. Linear fit: 0.656. Mika and Dawson [18]. Linear fit: 0.95. Current simulations: linear fit for small strains: 0.83; idem for large strains: 0.69 |
The current model assumes that the dislocation structures formed inside each grain are responsible for both strain rate and spin. In such a way two companion grains will be allowed to freely deform following the rules coming from Taylor or SC models but spinning together like a unique entity. Statistically, each grain will represent only half of a grain, which other part is assigned as a companion to other randomly chosen grain. The two parts forming the same grains are initially oriented in the same direction but will spin and deform following the closest influence of the first neighbor. From the statistical viewpoint it is not even necessary to have both fractions present. The many randomly chosen grains, representative of the starting texture, are capable of representing the textures in a statistical sense [16]. |
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The volume fraction can be
controlled by the relative size of both ellipsoids, with both close
companions always belonging to different phases, or by the number of
grains assigned to each phase with mixed-phases and one-phase pairs
statistically proportional to the volume fraction. No
large differences were found by using both approaches and the first one,
being cheaper in terms of computational time, was chosen. |
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FEM
model and coupling strategy
The
velocity field and pressure distribution, solution of the boundary problem
over the sample, is provided by the finite element method. We assumed that
inertial effects and body forces in the global balance and the elastic
components are negligible. The basic equations are solved using a finite
element discretization over the workpiece volume. In standard form we
found:
The
evolution of the deformation was calculated using an Eulerian scheme. The
resolution method is based on a velocity-pressure formulation: v
(velocity field), P (pressure field).
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Fig. 2: FEM mesh used to perform 12 successive wire drawing processes of 0.25 equivalent Von Mises strain each |
The
discretization equation leads to the classic system of linear algebraic
equations to get the velocity and pressure fields. The discretization is
performed using 8 nodes brick elements. The interpolation of the
velocity field is linear, and the pressure field is assumed constant
inside each element (elements P1-P0). The pressure term is integrated
using only one Gauss point localized in the center of the element while
other volumetric terms are integrated using usual 8 Gauss points. |
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Once
the convergence is achieved, the streamline concept appears naturally and
it can be followed from the elements localized in equivalent positions in
the successive homomorphic transversal sections. The strain path
calculation is obtained immediately from the streamline and constitutes
the input for the texture calculation. c |
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Results and discussion Due
to the high combined crystal and sample symmetry the textures will be
shown as inverse pole figures. Fig.
3 a) shows the texture simulated under the assumption of homogeneous
deformation at both macroscopic and microscopic levels (Case 1). The
sharpness is 50 and 10 times larger than the experimental values,
respectively for Cu and Fe, showing the known result of excessively
intense simulated textures by comparison with experiments. Fig
3 b) shows the texture simulated under the assumption of a unique source
of heterogeneity provided by the grain fragmentation (Case 2). This is the
less likely behavior but it is included, by the sake of completeness, to
compare the relative influence of each mechanism. The dramatic influence
of co-spin over texture sharpness is considered credible, judging by the
current results, because of other two new features. Cu texture slightly
develops the (112) component present in the experiments and Fe texture
develops an incomplete fiber going from (011) component to (113)
direction. An unwanted result is the division of the (101) component
creating a lower (203) component that has no similar in experiments. The
influence of macroscopic change of velocity gradient over texture, without
any other source of heterogeneity, is shown in Fig. 3 c). The macroscopic
heterogeneity is able to generate Fe fiber and slightly reduce the
strength of both textures. The Cu (112) component is barely growing but
most likely due to a simple smoothing process. By
allowing pairs of grain to co-spin the intra-grain heterogeneity is
induced and the results are shown in Fig. 3 d). Most components are shown
but they lack the right strengths and locations. Fig.
3 e) shows the influence of the usual grain-to-grain variations calculated
by SC models (Case 5). It is worthy to say some few words regarding stress
exponents and interaction between phases. The strain rate sensitivity
obtained from an experiment, at the same temperature from a wire drawing
experiment in single phase materials, could not be representative of the
current behavior because the interaction between both phases could impose
quite different behaviors to them [21,22]. However it is known that high
symmetry metals show very low strain rate sensitivity regardless of
texture. Thus, poly-crystal stress exponents are assumed representative of
single crystal behavior. Stress exponents of 100 and 50 for Cu and Fe were
used as coming from previous experiments and were found to be
reasonable values to achieve a fair match with experimental
textures. Summing
up the results: a)
Main components are qualitatively well simulated by all models. b)
Minor components are shown by different combinations of three
effects: b1)
Sachs behavior and co-spin tend to explain, in some degree, the emergence
of the Cu (112) component. b2)
Co-spin and macroscopic heterogeneity tend to explain (101)-(113) fiber in
Fe. c)
Minor
and main sharpness of all components are quantitatively well simulated
just by concurrence of all three levels of heterogeneity. Some
questions arise from the following criticism: improbability of having a
casual combination of two or three different causes contributing to the
same result. Analyzing the nature of the main and minor components can
shed light on the general behavior and elucidate the underlying phenomena
in all mechanisms. Main components, (001) and (111) for Cu and (101) for
Fe, are called stable components. The grains tend to spin reaching those
orientations and permanently settling there, provided that the strain path
is not changed. Stable components are usually developed when the velocity
gradient has no unti-symmetrical components included (no spins). When
spins are included, whether they come from macroscopic set-up
(case of pure shear vs. simple shear, Bolmaro et al.[25]) or from
redundant local velocity gradients (microscopic heterogenities) the trend
is to develop unstable components. Those unstable components are
permanently fed with new grains, which are lately drawn out of those
orientations due to the spin component. Either by enforcing macroscopic
spin (FEM) at
different
radii of the sample or by the SC spin calculated for each grain (SC
models) or spin sharing between grains we make the orientation of the
grains become unstable and create intermediate components. In fact we
found that the orientation of the minor components is very sensitive to
the die angle of extrusion (more or less determining the macroscopic
spin), stress exponent (influencing
the SC microscopic spin) or spin sharing magnitude (microscopic
intra-grain spin). In the limit of Sachs assumption the shear component
is, in average, approximately 10% of the total strain.
That
deviation is accompanied by a larger SC spin component. |
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| Fig 4 a). Experimental intensities for section <100> a <111> of the IPF for different deformation stages. b) behavior obtained by applying SC simulation plus spin sharing assuming a macroscopic homogeneous situation (Case 3). | |
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Regarding
sharpness, the simulations appear much more intense than the experimental
ones for Case 1 and with decreasing sharpness by adding different
combinations of heterogeneity levels. Fig. 3 h) (Case 8) shows an almost
perfect agreement with experimental results, exception made of a lack of
well balanced distribution of (001) and (111) components in the Cu phase
and because the (112) component, present in the experimental data, has
slightly moved to larger indexes (around (225)). |
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| Fig 5. a) Curling effect induced by the Fe grains over both phases. b) Geometry and orientation of grains provided by the SC model for large stress exponents. | |||||||||||||||||||||||||
Fig. 6. Fe (110) Pole Figure with respect to ellipsoidal axes showing the preferential orientation of (100) direction along the shortest axes. Ellipsoid axes are not on scale. |
The well-known curling effect is also partially tractable with the current model [26]. Each Eshelby tensor was updated independently for each grain together with orientation and axes for each hole. We obtained, at Von Mises equivalent deformation =3.0, ribbon like grains with relative axes lengths of a1= 0.12, a2= 0.71 and a3= 11.93 leading to an aspect ratio a2/a1= 7. That aspect ratio is in close agreement with experimental results obtained in a few two-phase materials [27-28]. It is clear that real curling effect can not be obtained in the sense that Cu and Fe develop a bent entanglement only likely to be achievable by a finer scale FEM simulation.
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Current simulations show that
the interaction between Fe and Cu induce a plane strain deformation also
for Cu phase. The aspect ratio of the shortest dimensions of grains is
however much smaller, reaching a value of 3 at the largest deformation (Table
I). Fig. 5 a) shows schematically a mixture of Cu and Fe crystals
deformed by wire drawing. In this case the interaction coefficient is
representative of the constraints exerted by the Fe presence. Cu by itself
is not prone to develop plane strain under uniaxial deformation but the Fe
grains are acting as internal tools over Cu phase. Besides deforming in
plane strain, the Fe crystals enforce plane strain over the Cu phase. The
crystal bending around the longitudinal axes does not contribute much to
texture development because of the high symmetry of the test. Fortunately
for the model the situation depicted in Fig. 5 b) is close enough to
situation 5 a) in terms of texture developments. Fig. 6 shows results
obtained for the orientation of Fe crystals with respect to the ellipsoids
representative of the matrix holes where the crystals are located. It is
clear that the main orientation along the longest ellipsoid axes is one of
the <011> while the shortest is a <100> and the intermediate
one is another <011>. Preferential orientations, with respect to the
ellipsoid axes, is not so well developed for the Cu phase except for a
preferential orientation along the longest axes in coincidence with the
<112> crystalline orientation. This is a new result coming out from
the simulations that should be confirmed by local measurements through
EBSD techniques. It
is not expected in any case that the co-spin model hold for larger
deformations. For heavily deformed Cu-Nb wire drawn samples a few authors
have observed Nb crystals almost free of dislocations [27-29]. The
deformation mechanism has been substituted at that deformation (Von Mises
equivalent deformation = 9 ) by a dislocation shuttling between both sides
of each grain. The grain boundaries are apparently acting as dislocation
sources and sinks. In such situation the textures should develop further
and misorientation between grains would not be kept constant, even not
approximately. Finally,
we have to keep in mind that the texture intensities are obtained without
any Gaussian smoothing and comprise, for the FEM-micromechanics
simulations, 30000 grains distributed in 5o x 5o x 5º
bins in the Eulerian orientation space. It means that, to get the
current numerical values, numerical massage has been kept at the minimum
possible. Conclusions The
simulated textures show the expected symmetries and patterns in each case.
Weakening process, in the average texture, is due to the superposition of
the different element patterns, consequence of radial variation of
velocity gradient (1st kind or macroscopic), grain-to-grain
heterogeneity (2nd kind) and intra-grain heterogeneity (3rd
kind or microscopic). Clearly all levels of heterogeneity must be included
to achieve texture sharpness results close enough to experimental values.
Otherwise the inference of hardening parameters, stress exponents, etc. by
means of simulation approaches can be misleading. The
three levels of heterogeneity have been shown contributing to the build up
of minor texture components, and partial depletion of mayor ones, in
different degrees. When the contributions of more of one level are shown
the mechanisms are clearly complementary and due to the same underlying
phenomena. The
simulated texture intensities are lower than the experimental values in
Fe, may be due to an overestimation of the misorientation effect obtained
through co-spin between companion grains. Notwithstanding the very simple
scheme of having co-spinning grains, even in absence of macroscopic
heterogeneity, takes the texture sharpness to values very close to
experimental ones. A
discussion is due to the large values of stress exponents usually coming
from experiments and simulations for metals and alloys. Other than the
fact that we are enforcing plane strain, they can also be rationalized
understanding the presence of just a few slip systems in a sole grain
(which takes the exponent n to higher values) as a consequence of
fragmenting grains. The rate independence law for metallic materials would
naturally induce fragmentation. Different parts of a grain are subject to
slightly different velocity gradient fields and compatibility is achieved
by averaging over a few of those different fractions. In the current
simulations the number of slip systems is kept around 2.5 in average for
Cu and Fe along the whole deformation process. A
search and checking, either from experiments or simulations, for the best
parameters (n exponents, hardening laws, interaction coefficients, etc.)
was performed exhaustively for the macroscopically homogeneous cases. The
search could not be done as exhaustively as in that case for the FEM based
simulations due to the larger computing time. However, the paper shows the
capability of the model to integrate all three major levels of
heterogeneity in a still computationally tractable way. References 1.- R.E. Bolmaro, R.A. Lebensohn and H.-G. Brokmeier. Comp. Mat. Sci., 9 (1997) 237-250. 2.- R.E. Bolmaro, A. Fourty, A. Roatta, M.A. Bertinetti and J. Signorelli. Scripta mater. 43 (2000) 553-559. 3.- P.R. Dawson and A. J. Beaudoin. J. of Metals, 49, 34, 1997. 4.- T. Aukrust, S. TjÆtta, H. E. Vatne and P. Van Houtte. Int. J. of Plast., 13, 111, 1997. 5.- D.A. Hughes and N. Hansen. Acta mater 45, 3871, 1997. 6.- Q. Liu, D. Juul Jensen, and N. Hansen. Acta mater 46, 5819, 1998. 7.- N. Hansen and D. Juul Jensen. Phil. Trans. R. Soc. Lond. A 357, 1447, 1999. 8.- H.-G. Brokmeier, U. Zink, R. Schnieber, B. Witassek, Mat. Sci. Forum 273-275, 277-282, 1998. 9.- J.S. Kallend, U.F. Kocks, A.D. Rollett, and H.-R. Wenk, Mat. Sci. Eng. A 132, 1-11, 1991. 10.- See web page at http://www.seismo.berkeley.edu/~wenk/beartex.htm 11.- R.E. Bolmaro, A. Fourty and H.-G. Brokmeier. Text. and Micr., 33, 125, 1999. 12.- R.A. Lebensohn and G.R. Canova. Acta mater., 44, 3687, 1997. 13.- A.Molinari, G.R. Canova and S. Ahzi. Acta metall., 35, 2983, 1987. 14.- J.W. Hutchinson, Proc. Roy. Soc. London A348, 101, 1976. 15.- P.A. Turner, C.N. Tomé, N. Christodoulou and C.H. Woo. Phil. Mag. A79, 10, 2505-2524,1999. 16.- R.E. Bolmaro, A. Roatta, A. Fourty, C.T. Necker and J. Bingert. Proceedings ICOTOM XII. Szpunar, J.A. Ed. National Research Council Press, 358-363, 1999. 17.- D.A. Hughes, Q. Liu, D.C. Chrzan and N. Hansen. Acta mater., 45, 105, 1997. 18.- D.P. Mika and P.R. Dawson. Acta mater., 47, 1355, 1999. 19.- D.A. Hughes and N. Hansen. Acta mater., 45, 3871, 1997. 20.- J.W. Signorelli, PhD Thesis. Rosario National University. Argentina , 1999. 21.- U.F. Kocks, Mat.Sci. Eng., A175, 49-54, 1994. 22.- H. Mecking and D. Dunst, Mat.Sci. Eng., A175, 55-62, 1994. 23.- G.Z. Sachs, Der Verein dutsher Ingenieur, 72, 734, 1928. 24.- W. Gambin and F. Barlat, Int. J. Plast., 13, 75-85, 1997. 25.- R.E. Bolmaro and U.F. Kocks, Scripta mater., 27, 12, 1717, 1992. 26.- J.D. Verhoeven, L.S. Chumbley, F.C. Laabs and W.A. Spitzig. Acta metall. mater., 39, 2825, 1991. 27.- F. Dupouy, E. Snoeck, M.J. Casanove, C. Roucau, J.P. Peyrade and S. Askénazy. Scripta mater. , 34, 1067, 1996. 28.- E. Snoeck, F. Lecouturier, L. Thilly, M.J. Casanove, H. Rakoto, G. Coffe, S. Askénazy, J.P. Peyrade, C. Roucau, V. Pantsyrny, A. Shikov and A. Nikulin. Scripta mater. , 38, 1643, 1998. 29.- S.I. Hong and M.A. Hill, Mat. Sc. Eng. A281, 189, 2000.
Acknowledgements: Table I Main mechanical parameters. Inputs and
outputs of the simulations
Figure captions
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Fig. 3. Simulations performed by: a) Case 1.Taylor assumption of equal deformation for each grain. b) Case 2. Taylor model but allowing grains to fragment by using the co-spin scheme. c) Taylor model plus Heterogeneous macroscopic deformation. d) Taylor model, heterogeneous macroscopic strain and co-spin. e) Case 3. Grain to grain heterogeneity calculated by SC models. f) Case 4. Considering microscopic heterogeneity stemming from grain fragmentation by using the SC model under the assumption of spin sharing between grains. g) Case 5. Superposition of the different velocity gradients in the final layer of the FEM mesh without spin sharing. h) Case 6. Considering a combined action of microscopic (fragmentation simulated by spin sharing and grain to grain heterogeneity by SC models) and macroscopic (different velocity gradients obtained by FEM) heterogeneities. Experimental texture. i) Inverse pole figures for 25%Cu-75%Fe powder composite. Wire drawn until Von Mises equivalent deformation of 3.0. All results in log scale. |
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