Discrete element modeling of powder consolidation and the formation of titanium-matrix composites from powder-fiber monotape

A three year research effort is completed with the development of the Discrete Element Consolidation Analyzer (DECA) for process modeling the formation of titanium composites from powder-fiber monotapes. The primary goal of the DECA process model is to provide a statistically realistic analysis of the various physical processes necessary to achieve higher quality composites from the powder-fiber technique. Over the course of this effort, research and code development was conducted in three distinct stages. The first stage focused on the simulation of initial geometry of the powder and fibers as well as the evolution of tape configuration during the pre-consolidation processing steps. The second stage developed the mechanics of the discrete element powder consolidation and the material characterization methods necessary to model the viscoplastic response of the powder to transient thermal and mechanical boundary conditions. The final stage incorporated the presence of fibers to evaluate the interaction mechanics and possible fibers damage resulting from discrete powder-fiber contacts. As a conclusion to the research, DECA model predictions of density versus time for various consolidation profiles are directly compared to actual consolidation test results and a DECA prescribed process profile is used to fabricate a 6$sp{primeprime} times$ 6$sp{primeprime}$ composite panel of Ti-6242/SCS-6.;In completing this research, the discrete element modeling technique has proven to be a powerful tool for the analysis and simulation of metal powder consolidation as well as the consolidation of metal matrix composites. The DECA code orchestrates the use of particle kinetics, some simple aspects of gas dynamics, elasticity, plasticity, creep and various innovative material characterization methods to produce a seamless analysis for powder metallurgy processing of composites. Through the application of the DECA capability, many aspects of the processing stages have been elucidated for further investigation and possibly for optimization to in the end provide the underlying goal of increasing quality and reduce cost of producing composites from the powder-fiber monotape method.;As a minimum, it was desired that the resulting code provide an accurate prediction of relative density as a function of applied pressure, temperature, and time. This goal was achieved. However, it was later realized that under specific conditions of pre-heat and unidirectional compaction, the rate change in relative density could be determined by the rate of applied load. With the appropriate control and load capacity, densification by plasticity and transient creep mechanisms can achieve complete void removal. Unfortunately, the real world doesn't work with 1$sp{primeprime} times$ 1$sp{primeprime}$ samples and the pressurization rates attained by most HIP units are several orders of magnitude below those specific conditions in which it is possible to essentially "hammer" the voids out of the composite. As a result, it was learned that under certain conditions Ti-6242/SCS-6 monotape (temperature between 1650$spcirc$F and $beta$-transus with a loading rate greater than 10 kips/min.), it is possible to consolidate Ti-6242/SCS-6 monotape composite in a matter of minutes without damaging fibers. (Abstract shortened by UMI.).