Micromechanical models of delamination in aluminum-lithium alloys

Aluminum lithium (Al-Li) alloys are lighter, stiffer, and tougher than conventional aerospace aluminum alloys. Replacing conventional aluminums with Al-Li could substantially decrease the weight and cost of aerospace structures. However, Al-Li alloys often fracture intergranularly via a mechanism called delamination cracking. While secondary delamination cracks can improve the effective toughness of a component, no current model accurately predicts the initiation and growth of intergranular cracks. Since simulations cannot incorporate delamination into a structural model, designers cannot quantify the effect of delamination cracking on a particular component. This uncertainty limits the application of Al-Li alloys. Previous experiments identify microstructural features linked to delamination. Fractography of failed surfaces indicates plastic void growth triggers intergranular failure. Furthermore, certain types of soft/stiff grain boundaries tend to localize void growth and nucleate delamination cracks. This dissertation develops a mechanism for the initiation of delamination on the microscale that accounts for these experimental observations. Microscale simulations of grain boundaries near a long primary crack explore the delamination mechanism on the mesoscale. In these simulations, a physically-based crystal plasticity (CP) model represents the constitutive response of individual grains. This CP model incorporates plastic voriticity correction terms into a standard objective stress rate integration, to accurately account for the kinematics of lattice deformation. The CP model implements slip system hardening with a modular approach to facilitate quick testing and calibration of different theories of hardening. The microscale models reveal soft/stiff grain boundaries develop elevated mean stress and plastic strain as a consequence of the mechanics of the interface. These elevated stresses and strain drive plastic void growth. The results indicate plastic void growth localizes to the grain boundaries even without the presence of material defects, such as precipitate free zones. Microscale simulations also explain the strong T -stress effect often observed in experimental fracture tests on Al-Li alloys. Finally, this dissertation develops a multiscale model of intergranular damage that incorporates the results of the microscale CP simulations. The multiscale model represents the mechanics of microscale deformation near grain boundaries with a simplified compatibility/equilibrium method. The intergranular stresses and strains from the simplified interface model drive a microscale damage index based on the physics of plastic void growth. Finally, a mesh-size independent scheme homogenizes damage on many grain boundaries into a macroscale damage index and projects the damage index to fail a plane of a macroscale structural model. The multiscale damage model, applied to 2195 Al-Li, successfully predicts delamination crack growth in a variety of standard experimental test configurations. The model correctly represents the microscale physics of delamination initiation and growth; after calibration to experimental data it can reliably predict the growth of delamination cracks in a component with any material configuration and loading. Therefore, the multiscale damage model forms the basis of a simulation method that allows designers to predict the development and net effect of delamination cracking in a structural model – facilitating the application of lightweight Al-Li alloys in high-performance aerospace structures.

Name thesis:degree_name

Ph.D.

Level thesis:degree_level

Dissertation

Discipline thesis:degree_discipline

Civil Engineering

Grantor

University of Illinois at Urbana-Champaign

Year dc:date

2014

Author dc:creator

• Messner, Mark

Contributors dc:contributor

• Dodds, Robert H., Jr.
• Beaudoin, Armand J.
• Sehitoglu, Huseyin
• Duarte, C. Armando

• Aluminum-lithium
• Delamination
• Fracture mechanics
• Crystal plasticity
• Multiscale model

Statement dc:rights

• Copyright 2014 Mark Christian Messner

Language dc:language

en

Handle dc:identifier

http://hdl.handle.net/2142/50707

OAI identifier oai:identifier

oai:www.ideals.illinois.edu:2142/50707