Institute of Fundamental Technological Research

As the critical feature of the stick-slip for soft materials, the interfacial Schallamach waves of flexible composite structures are essential for smart tactile sensors to realize sliding perception. Herein, the Schallamach waves of polydimethylsiloxane film/substrate bilayer structures with three substrate stiffnesses regulated by porosities are investigated by setting up in-situ sliding tests and establishing finite element models with mixed-mode cohesive contact. Inhomogeneity in microcontact stiffness disrupts the continuity and synchronization of the Schallamach waves, resulting in non-periodic fluctuations in the contact force. The buckling phenomenon of the film structure marks the transition from stick to slip. This buckling induces a shift at the crack front from normal compressive stress to tensile stress, leading to mixed-mode damage.

Stick-slip,Polydimethylsiloxane film/substrate bilayer structures,Schallamach wave,In-situ sliding test,Mixed-mode cohesive contact model

Due to the nonlinear coupling, assessing the direct effect of temperature on magnetic flux leakage (MFL) signal is a complicated task. If temperature induces inner stress, it makes the problem doubly difficult, so few models are available for predicting the MFL signal under this condition. To model the effect of temperature on MFL signal, the temperature-dependent magnetic dipole models are proposed. In the first case, where the direct thermal effect is involved only, the dipole model is improved via the modified temperature-dependent Jiles-Atherton (J-A) model. While in the second case, where the combined effects of temperature and thermal stress are considered, the magnetomechanical J-A parameters are further introduced into the dipole model. The thermal stress distribution around a cylindrical through-hole defect is solved by thermoelastic and solid mechanics theories. The magnetomechanical theory is employed to analyse the stress-dependent magnetisation distribution, the key parameter in the magnetic dipole model. The verified experiments are conducted on an M250-50A non-oriented grain (NO) silicon steel specimen with a cylindrical through-hole defect. And the MFL signals predicted by both proposed models agree with the experimental results. When the direct effect of temperature is involved only, the peak-to-peak amplitude of the MFL signal (MFLpp) presents approximately linear dependence on temperature in the range from −40 to 60 . In addition, when both temperature and thermal stress are considered, the MFLpp changes as a parabolic function of temperature, this being much more significant than the direct effect. The proposed models can act as effective tools to understand the temperature and thermal stress influences on MFL signals. They are also appropriate to solve the inverse problem of sizing the defects accurately when the temperature is involved.

Magnetic dipole model, Magnetic flux leakage, Temperature, J-A model, Thermal stress, Magnetomechanics

Carbon steel has proven to be an important structural and functional material that plays an irreplaceable role in the worldwide economy. The influence of carbon on the mechanical and magnetic properties of the steel is well understood. Thus, the precise knowledge of the amount of carbon content in steel is crucial. Magnetic Barkhausen noise (MBN), magnetic hysteresis loop (MHL) and impedance measurements are reliable tools to assess carbon content. In this work, a multifunctional induction coil sensor used for MBN, MHL and impedance measurements is designed and optimised. A multifunctional measurement system using the optimised induction coil is employed to measure MBN, MHL and impedance signals. The parabolic dependence of the maximum value of MBN envelope on carbon content in steel is theoretically analysed and experimentally verified. Coercive field and remanence from MHL measurements as well as the maximum impedance value are found to be proportional to carbon content and their dependence is explained with analytical simulations.

Carbon content ,Impedance ,Magnetic Barkhausen Noise ,Magnetic Hysteresis Loop ,Multifunctional sensor

The effect of temperature on magnetic Barkhausen noise (MBN) can be divided into two types: the direct effect of temperature itself and the indirect effect of thermally induced stress. The theoretical model is proposed in this paper to describe the effects of temperature on the MBN signal. For the case considering the direct effect of temperature only, the analytical model allows the prediction of the effect of temperature on MBN profile, and, based on the model, a simple linear calibration curve is presented to evaluate the effect of temperature on MBN amplitude quantitatively. While for the case where the indirect effect of thermal stress is taken into account in addition to the direct effect, the proposed theoretical model allows the deduction of parabolic function for quantitative evaluation of the combined effect on MBN. Both effects of temperature on MBN, i.e., the direct only and the combined one, have been studied experimentally on 0.5 mm thickness non-oriented (NO) electrical steel and the adhesive structure of NO steel and ceramic glass, respectively. The reciprocal of the measured MBN peak amplitude (1/MBNp) in the first case shows a linear function of temperature, which agrees with the proposed linear calibration curve. While in the experiments considering the combined effects, 1/MBNp shows parabolic dependence on temperature, which is further simplified as a piecewise function for the practical applications.

magnetic Barkhausen noise, temperature, thermal stress, nondestructive evaluation

The interfacial heat transfer coefficient (IHTC) for titanium alloys is an important parameter in non-isothermal hot stamping processes to determine the temperature field as well as temperature-dependent material behaviours that consequently affect the post-form properties of the formed components. However, the IHTC for titanium alloys in hot stamping processes has seldom been studied before. In the present research, the effects of contact pressure, lubricant, surface roughness, tooling material and initial blank temperature on the IHTC for the titanium alloy Ti-6Al-4V were studied and modelled to characterise the IHTC values under various hot stamping conditions as well as identify the functional mechanisms affecting the IHTC. Furthermore, the results of hot stamping of Ti-6Al4V wing stiffener components were used to verify the simulation results of the temperature field of the formed component with an error of less than 5%.

interfacial heat transfer coefficient (IHTC), Ti-6Al-4V, hot stamping, experimental validation

Assessing the effect of defect induced stresses on magnetic flux leakage (MFL) signals is a complicated task due to nonlinear magnetomechanical coupling. To facilitate the analysis, a multi-physics finite elemental simulation model is proposed based on magnetomechanical theory. The model works by quasi-statically computing the stress distribution in the specimen, which is then inherited to solve the nonlinear magnetic problem dynamically. The converged solution allows identification and extraction of the MFL signal induced by the defect along the sensor scanning line. Experiments are conducted on an AISI 1045 steel specimen, i.e. a dog-bone shaped rod with a cylindrical square-notch defect. The experiments confirm the validity of the proposed model that predicted a linear dependency of the peak-to-peak amplitude of the normalized MFL signal on applied stress. Besides identifying the effect of stress on the induced MFL signal, the proposed model is also suitable for solving the inverse problem of sizing the defects when stress is involved.

magnetic flux leakage, magnetomechanics, Jiles–Atherton model, non-destructive testing, finite element method, multiphysics numerical simulation

Near-α titanium alloys have extensive applications in high temperature structural components of aircrafts. To manufacture complex-shaped titanium alloy panel parts with desired microstructure and good properties, an innovative low-cost hot stamping process for titanium alloy was studied in this paper. Firstly, a series of hot tensile tests and Scanning Electron Microscope (SEM) observations were performed to investigate hot deformation characteristics and identify typical microstructural evolutions. The optimal forming temperature range is determined to be from 750 °C to 900 °C for hot stamping of TA15. In addition, a unified mechanisms-based material model for TA15 titanium alloy based on the softening mechanisms of recrystallization and damage was established, which enables to precisely predict stress-strain behaviors and potentially to be implemented into Finite Element (FE) simulations for designing the reasonable processing window of structural parts for the aerospace industry.

TA15, hot stamping, phase evolution, deformation, modelling

A novel hot stamping process for Ti6Al4V alloy using cold forming tools and a hot blank was presented in this paper. The formability of the material was studied through uniaxial tensile tests at temperatures ranging from 600 to 900 °C and strain rates ranging from 0.1 to 5 s-1. An elongation ranging from 30% to 60% could be achieved at temperatures ranging from 750 to 900°C respectively. The main microstructure evolution mechanisms varied with the deformation temperature, including recovery, phase transformation and recrystallization. The hardness of the material after deformation first decreased with the temperature due to recovery, and subsequently increased mainly due to the phase transformation. During the hot stamping tests, qualified parts could be formed successfully at heating temperatures ranging from 750 to 850°C. The forming failed at lower temperatures due to the limited ductility of the material. At temperatures higher than 900°C, extensive phase transformation of α to β occurred during the heating. During the transfer and forming, the temperature dropped significantly which led to the formation of transformed β, reduction of the formability and subsequent failure. The post-form hardness distribution demonstrated the same tendency as that after uniaxial tensile tests.

titanium alloys, Ti6Al4V, hot stamping, microstructure

To investigate the feasibility of a novel hot stamping process for the Ti6Al4V titanium alloy using low temperature forming tools, mechanical properties of the material were studied using hot tensile tests at a temperature range of 600 - 900°C with a constant strain rate of 1s-1. Hot stamping tests were carried out to verify the feasibility of this technology and identify the forming window for the material. Results show that when the deformation temperature was lower than 700°C, the amount of elongation was less than 20%, and it also had little change with the temperature. However, when the temperature was higher than 700°C, a good ductility of the material can be achieved. During the forming tests, parts failed at lower temperatures (600°C) due to the limited formability and also failed at higher temperatures (950°C) due to the phase transformation. The post-form hardness firstly decreased with the temperature increasing due to recovery and then increased due to the phase transformation. Qualified parts were formed successfully between temperatures of 750 - 850°C, which indicates that this new technology has a great potential in forming titanium alloys sheet components.

titanium, hot stamping, metal forming