As part of the LightForm Programme, our project is focused on numerical modelling of forming processes and constitutive material behaviour:

  • Finite element modelling of hot compression tests of Ti64, Ti-407 and Zr2.5Nb. The modelling aims to account for effects such as barrelling due to friction and temperature gradient, providing true σ(ε,ε ̇,T) for FE or microstructural modelling. 

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Figure 1. Distribution of von Mises equivalent strain in hot compression of Zr2.5Nb

 

  • Developing constitutive material models of Ti64, Ti-407, Zr2.5Nb and wrought Al alloys, testing the validity of, and sensitivity to, conventional empirical fits, such as the hyperbolic sinh/Zener-Hollomon equation, modified Johnson-Cook models;  development of microstructure-informed finite element models. Experimental work to provide data for validation of the modelling, in collaboration with The University of Manchester.
  • Finite element analysis of innovative processes for light alloys, such as friction welding, hot form quench (HFQ), and flexible forming.

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Figure 2. Mapping heat generation onto constitutive data in a material deformation map.

 

  • Microstructure evolution models based on thermomechanical histories and microstructural data from real process or lab-scale tests (identifying microstructural state variables, initial microstructure, and its evolution as a function of temperature, strain-rate and time).