Mahesh Sivasambu

Pilgering is a complex incremental manufacturing process for seamless tubes. In this work, a miniature physical simulator for pilgering was designed and fabricated. This miniature simulator employs a grooved roll-die and a mandrel and can impose controlled reductions in both tube diameter and wall thickness. Pilgering deformation over a range of ratios of reductions in wall thickness and in tube diameter, known as the Q-factor, was imposed on hemi-cylindrical zirconium alloy specimens. The influence of the Q-factor on the microstructure and deformation texture of the deformed specimens was quantified. A polycrystal plasticity calculation based on the binary tree model was used to simulate texture evolution during the simulated pilgering process. The computer model quantitatively captured the variation with Q of the Kearns factors, as measured in the physically simulated specimen. The small differences noticed between the predicted and experimental final textures point to unaccounted transverse components of the flow field. These observations suggest that physical and/or computer simulations can form the basis of a rapid methodology for tool selection to realize prescribed post-pilgering textures.

Mechanical properties at ambient and cryogenic temperatures of Al-Cu-Li alloy are required for design and fabrication of liquid hydrogen and liquid oxygen tanks of satellite launch vehicles. In the present work, bead-on-sheet, friction stir welding was carried out with three different rotation speeds. The yield and strain hardening behaviors of the welds were evaluated in temperature range of 20 K to 298 K. Both yield stress and strain hardening ability in the specimen increased with decrease in testing temperature. The dependence of yield stress on temperature was modeled on the basis of thermally activated dislocation mobility, while that of strain hardening was modeled on the temperature dependence of dynamic recovery rate parameter. The recovery parameter followed an Arrhenius-type relationship with temperature. The model parameters determined from the experimental data were further used to simulate the stress–strain curves at different sub-zero temperatures for the friction stir welds.

Fully recrystallized commercial Zirconium plates were subjected to uniaxial tension. Tests were conducted at different temperatures (123 K - 623 K) and along two plate directions. Both directions were nominally unfavorable for deformation twinning. The effect of the working temperature on crystallographic texture and in-grain misorientation development was insignificant. However, systematic variation in work hardening and in the area fraction and morphology of deformation twins was observed with temperature. At all temperatures, twinning was associated with significant near boundary mesoscopic shear, suggesting a possible linkage with twin nucleation. A binary tree based model of the polycrystal, which explicitly accounts for grain boundary accommodation and implements the phenomenological extended Voce hardening law, was implemented. This model could capture the measured stress-strain response and twin volume fractions accurately. Interestingly, slip and twin system hardness evolution permitted multiplicative decomposition into temperature-dependent, and accumulated strain-dependent parts. Furthermore, under conditions of relatively limited deformation twinning, the work hardening of the slip and twin systems followed two phenomenological laws proposed in the literature for non-twinning single-phase face centered cubic materials.

Friction stir welds (FSWs) can be considered as an ensemble of elements of material with composite microstructures connected in series. In the present study, bead-on-plate FSW runs were made on an Al–Cu–Li alloy with varying rotation speeds ranging from 400 to 800 rpm. Microstructure of the FSW region was investigated by using optical microscope, electron backscattered diffraction (EBSD) and transmission electron microscope (TEM). Thermal stability of various precipitates was evaluated with differential scanning calorimetry (DSC) measurements. Strength variation across FSW cross sections was mapped by microhardness measurements. Average as well as local mechanical properties were evaluated using a digital image correlation (DIC) technique. Irrespective of the process parameters, FSW samples showed similar tensile and strain hardening behaviour along with serrations in stress-strain curves while local strength values showed increasing trend with rotation speed. The FSW alloy produced at intermediate rotation speed exhibited different mechanical behavior and is correlated with the resultant substantial changes in the microstructure. Strain localization occurred at the boundary of nugget zone and thermo-mechanically affected zone which led to failure of the FSW tensile specimens within weld regions. Fractography investigation revealed that the failure is initiation controlled, that is void nucleation at coarse precipitate-matrix interfaces.

Deformation twinning was directly observed in three commercial zirconium alloy samples during split channel die plane-strain compression. One pair of samples had similar starting texture but different grain size distributions, while another pair had similar grain size distribution but different starting textures. Extension twinning was found to be more sensitive to the starting texture than to the grain size distribution. Also, regions of intense deformation near grain boundaries were observed. A hierarchical binary tree-based polycrystal plasticity model, implementing the Chin-Hosford-Mendorf twinning criterion, captured the experimentally observed twinning grains’ lattice orientation distribution, and the twin volume fraction evolution, provided the critical resolved shear stress for extension twinning, $$ \tau_{0} , $$τ0, was assumed much larger than any of the values reported in the literature, based on the viscoplastic self-consistent model. A comparison of the models suggests that $$ \tau_{0} $$τ0 obtained using the present model and the viscoplastic self-consistent models physically correspond to the critical stress required for twin nucleation, and twin growth, respectively.

The development of microstructure and crystallographic texture with effective strain at three through-thickness locations (near rolls, center, and near mandrel) in a partly pilgered Zircaloy-4 tube is described. Pilgering is found to eliminate through-thickness variation in grain size in the starting hot-extruded material and to generate location-dependent asymmetries in crystallographic texture. Deformation texture development during pilgering is modeled with polycrystal plasticity by idealizing the metal flow pattern as axisymmetric flow through a convergent channel. Good qualitative comparison of the predicted and experimental post-pilgering textures is obtained, provided location-dependent transverse shear component is superposed on the gross flow field, and localized deformation at grain boundaries is allowed. Frictional forces between tube and die are deduced from these observations.