A new spectral framework for crystal plasticity modeling of cubic and hexagonal polycrystalline metals

Crystal plasticity physics-based constitutive theories are used in understanding and predicting the evolution of the underlying microstructure and the concomitant anisotropic stress-strain response in polycrystalline metals subjected to finite plastic strains. A new scheme for efficient crystal plasticity computations for both cubic and hexagonal polycrystalline metals subjected to arbitrary deformation modes has been developed in this thesis. This new computational scheme involves building material databases comprised of spectral coefficients. These spectral coefficients are computed using discrete Fourier transforms (DFTs) and allow for compact representation and fast retrieval of crystal plasticity solutions for a crystal of any orientation subjected to any deformation mode. The novel approach is able to speed up the conventional crystal plasticity computations by two orders of magnitude. Furthermore, mathematical procedures for delineation of property closures that identify the complete set of theoretically feasible combinations of macroscale effective properties has been developed for a broad set of mechanical properties. Subsequently, these constructs were used in microstructure design for identifying an optimal microstructure for selected performance criteria. And finally, hybrid processing recipes that transform a given initial microstructure into a member of the set of optimal microstructures that exhibit superior properties or performance characteristics have been described. Insights and tremendous potential of these novel materials knowledge systems are discussed and demonstrated through specific case-studies.;The anisotropic stress-strain response measured in simple compression and simple tension tests in different sample directions on an annealed, strongly textured, AZ31 sheet has been studied. New insights into the mechanical response of this material were obtained by correlating the changes in the measured strain-hardening rates in the different experiments to the corresponding changes in the microstructure evolution are provided. Based on the experimental observations, a hypothesis is postulated for explaining the different morphologies of the extension and contraction twins, and the apparent tension/compression asymmetry exhibited by this alloy. The main elements of the hypothesis are then critically evaluated using finite element simulations of stress fields in various matrix-twin configurations subjected to a range of loading conditions.