Integrated Thermo-mechanical Processing, Microstructure and Property Simulation System for Aluminum Alloys

Currently, no single design tool can predict the coupled effects of alloy composition, thermo-mechanical processing, microstructure evolution, and crystallographic texture. A reliable through-process computational materials modeling system would represent a next-generation approach to alloy and process design. It will greatly reduce the risk to develop novel materials and processes, and accelerate the insertion of new products into industry from conception to implementation. Towards this goal, this project proposes to enhance the process modeling and microstructure evolution system, DEFORM, with a new precipitation model specific to the beta phase of 5xxx series aluminum alloys; to allow DEFORM to communicate with the commercial crystal plasticity code Crysp, for texture prediction; and to validate the texture modeling predictions via material testing and characterization. The resultant product will be able to model, in integrated fashion, the coupled effects of material composition, initial microstructure, and process variables on final part properties - flow stress for Phase I, with the future goals of modeling ductility and ultimate tensile strength in Phase II. Grain size evolution, precipitate formation, texture evolution, work hardening, recovery and recrystallization will all be modeled. Modeling results will be evaluated with experimental testing and characterization of aluminum alloys Al5083 and Al5456.