Critical Inclusion Size and Void Growth in Dual-Phase Ferrite-Bainite Steel During Ductile Fracture

doi:10.11900/0412.1961.2022.00293

Acta Metall Sin

2023, Vol. 59

Issue (5): 611-622 DOI: 10.11900/0412.1961.2022.00293

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Critical Inclusion Size and Void Growth in Dual-Phase Ferrite-Bainite Steel During Ductile Fracture

ZHAO Yafeng¹^,², LIU Sujie¹, CHEN Yun¹, MA Hui¹, MA Guangcai³, GUO Yi¹(

)

¹Shenyang National Laboratory for Materials Science, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China
²School of Materials Science and Engineering, Northeastern University, Shenyang 110819, China
³Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China

Cite this article:

ZHAO Yafeng, LIU Sujie, CHEN Yun, MA Hui, MA Guangcai, GUO Yi. Critical Inclusion Size and Void Growth in Dual-Phase Ferrite-Bainite Steel During Ductile Fracture. Acta Metall Sin, 2023, 59(5): 611-622.

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Abstract

Ferrite-bainite dual-phase steel is widely used in the automotive industry owing to its high strength and excellent ductility. The impact of inclusions and void growth behavior in dual-phase steel is a major concern among researchers seeking to achieve better mechanical properties. To investigate this, a cross-length-scale multimodal method was employed to study the influence of local microstructures on void growth during ductile fracture of a dual-phase ferrite-bainite steel. During tensile testing, laboratory X-ray computed tomography (XCT) was used to measure the evolution of void volume. 3D-electron back scatter diffraction (3D-EBSD) provided information about the voids nucleated at both inclusion particles and bainite phases or their boundaries. Carefully controlled, broad-focused ion beam excavation was performed to reveal a new interface at a specific depth of the voids. Results showed that voids resulting from large inclusions are significantly bigger than either small inclusions or the bainite phase. Large inclusions lead to large voids even when the strain correlated with the growth of those voids is lower. An investigation of the dislocation densities surrounding the voids suggested that they may be related to the strain gradient around the different inclusion sizes. A critical inclusion size estimated to be around 1.85-2.86 μm was found below which nucleation occurs but with limited growth. The elevated rate of local dislocation multiplication due to local deformation gradient effects can impede the growth of smaller voids. The growth of voids is heterogeneous, and their shape correlates well with the deformability of the surrounding grains, as indicated by a Schmid factor weighted using the grain size. This weighted Schmid factor explains not only the shape of the voids but also sheds light on the ease of void coalescence based on the microstructures separating the voids.

Key words: dual-phase ferrite-bainite steel void nucleation and growth 3D-EBSD X-ray computed tomography size effect

Received: 15 June 2022

ZTFLH:

TG142

Fund: National Natural Science Foundation of China(52201149);National Science and Technology Major Project(J2019-VI-0019-0134);Strategic Priority Research Program of Chinese Academy of Sciences(XDC04000000);ERC CORREL-CT Project(695638)

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	ZHAO Yafeng
	LIU Sujie
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	MA Hui
	MA Guangcai
	GUO Yi

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https://www.ams.org.cn/EN/10.11900/0412.1961.2022.00293 OR https://www.ams.org.cn/EN/Y2023/V59/I5/611

Fig.1 2D slice images of time-lap CT scans at different strain (ε) levels post ultimate tensile strength (UTS) (a-h) and stress-strain curve (i) (The rate of void nucleation increases rapidly between nominal strain of 0.05 and 0.053, which quickly coalesced and led to fracture)
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(a) ε = 0.038 (b) ε = 0.047 (c) ε = 0.049
(d) ε = 0.05 (e) ε = 0.053 (f) fracture
(g) slice at the fracture surface before fracture in Fig.1e (h) slice at the region of interest shown in Fig.1e

Fig.2 Equivalent diameters of two voids in Fig.1a as a function of true strain at the corresponding cross section of the sample (Each data point corresponds to a scan point marked in Fig.1i)
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Fig.3 Multimodal correlative approach to study void growth
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(a) XCT morphology of the fractured sample, voids coloured in red
(b) bulk cut out by PFIB at the corresponding location indicated by circle in Fig.3a
(c) serial sectioning 3D-EBSD reconstruction (~98 μm × 98 μm × 80 μm) of the cutted bulk shown in Fig.3b
(d) comparisons between 2D and 3D grain size distributions

Fig.4 High resolution XCT morphology of the two voids shown in Fig.1a together with the grains surrounding the two voids (a), illustration demonstrating void expansion caused by glide of dislocation loops (b—Burgers vector module) (b)
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Fig.5 EBSD band contrast maps (a-c) and EBSD maps colored with Euler angles (d-f) in low strained region showing the un-deformed images (a, d) and high strained regions featuring the mid cross section of void 1 (b, e) and void 2 (c, f)
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Fig.6 Sizes and types of void in the PFIB-SEM sampled volume (~98 µm × 98 µm × 80 µm) (a) and SEM images of voids type 1 (b), type 2 (c), and type 3 (d)
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Fig.7 Void size as a function of inclusion size
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Fig.8 Average geometrically necessary dislocation (GND) density in the vicinity of voids as a function of associated inclusion size

Fig.9 GND densities (ρ_GND) (a1, b1) and Schmid factors (a2, b2) of the left and right parts around the voids in Figs.9a3 and b3; and EBSD band contrast maps (a3, b3), Schmid factor distributions (a4, b4), weighted Schmid factor distributions (a5, b5), and GND density distributions (a6, b6) of void 1 (a1-a6) and void 2 (b1-b6)
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Material	μ / GPa	σ_y / MPa	$d σ d ε$ / MPa	r_c / µm
Low-carbon steel	80	295	200	2.06
Ferrite in ferrite-bainite dual-phase steel^[45]	72	370	106	2.51
Bainite in ferrite-bainite dual-phase steel^[45]	76	830	258	0.51
Ferrite in 600 MPa ferrite-martensite dual-phase steel^[46]	78	313	160	2.30
Martensite in 600 MPa ferrite-martensite dual-phase steel^[46]	79	1014	167	0.32
Ferrite in 1000 MPa ferrite-martensite dual-phase steel^[46]	78	443	141	1.85
Martensite in 1000 MPa ferrite-martensite dual-phase steel^[46]	79	813	280	0.52
Ferrite in ferrite-martensite dual-phase steel^[47]	79	260	159	2.86
Martensite in ferrite-martensite dual-phase steel^[47]	79	1000	460	0.26
Ferrite in ferrite-martensite dual-phase steel^[48]	77	430	117	2.24
Martensite in ferrite-martensite dual-phase steel^[48]	77	1450	431	0.18

Table 1 Critical particle sizes across various types of steels estimated according to Equation (6)

Table 2 Literature reports on the magnitude of the critical particle size across various types of steels^[48-56]

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