The study presents the results of research involving a comprehensive analysis of the wear of forming tools used for shaping clay strands intended for ceramic roof tiles during the extrusion process. The investigations initially focused on the analysis of key parameters recorded during industrial operation, namely extrusion pressure and the velocity of the extruded strand. Under operational conditions, previously untested material variants were evaluated, including C45 steel with a hardfacing layer and hot-work tool steel Orvar 2M. The measurement results were compared with the standard tool material commonly used in this application, namely the cold-work tool steel NC11LV. The use of hardfacing in this industrial application proved to be a valuable alternative, enabling the regeneration of worn tools. In contrast, the hot-work tool steel (Orvar 2M) demonstrated inferior performance under the analyzed industrial conditions, exhibiting the most intensive wear. The research was complemented by the development of a numerical simulation model of the process, which was essential for a comprehensive analysis and for understanding the causes of the observed tribological wear. Based on the modeling results, die design modifications were formulated to minimise the dead-zone effect and reduce the stresses acting on the forming tools. The final stage of the presented research involved identifying directions for future studies.

Proper mesh discretization plays a crucial role in the accuracy of simulations using the coupled Random Cellular Automata Finite Element (RCAFE) method for modelling complex microstructure evolution problems like dynamic recrystallization (DRX). The mesh quality directly impacts the stability, convergence, and precision of FE simulations, making it a critical factor in achieving reliable results in the RCAFE model. Traditional mesh generation techniques face significant challenges when handling complex geometries, ensuring adaptive refinement, and maintaining mesh quality in high-gradient regions or anisotropic material models. Therefore, this paper focuses on developing a solution for adaptive remeshing tailored to the specific needs of RCAFE DRX simulations within commercial finite element Abaqus software. The process involves designing material-specific meshes based on digital microstructure morphology, utilizing structured meshes for homogeneous materials and heterogeneous meshes for complex microstructures such as dual-phase steels or multi-phase composites. The developed algorithmic solutions for automation of mesh modifications corresponding to the evolving microstructure morphology are presented within the work. Such an approach enables the efficient creation of high-quality, material-specific meshes in each time step, thereby improving the robustness and efficiency of RCAFE simulations across diverse applications.

We summarize a data analysis approach for electron backscatter diffraction (EBSD) which uses high-resolution Kikuchi pattern simulations to measure isochoric relative deformation gradient tensors from experimentally measured Kikuchi patterns of relatively low resolution. Simulation-based supersampling of the theoretical test diffraction patterns enables a significant precision improvement of tensor parameters obtained in best-fit determinations of strains and orientations from low-resolution experimental patterns. As an application, we demonstrate high-resolution orientation and strain analysis for the model case of hardness test indents on a Si(100) wafer, using Kikuchi patterns of variable resolution. The approach shows noise levels near 1 × 10^-4 in the relative deviatoric strain norm and in the relative rotation angles on nominally strain-free regions of the silicon wafer. The strain and rotation measurements are interpreted by finite element simulations. While confirming the basic findings of previously published studies, the present approach enables a potential reduction in the necessary pattern data size by about two orders of magnitude. We estimate that pattern resolutions in the order of 256×256 pixels should be enough to solve a majority of EBSD analysis tasks using pattern matching techniques.

Titanium nitride (TiN) coated steel sheets are widely utilized across various industries, offering tailored solutions for diverse applications. Manufacturers appreciate its adaptability and precision, utilizing it to create intricate components for electronics, packaging, and specialized industrial equipment. In construction and design, TiN coated sheet enables crafting detailed architectural elements and custom fixtures, providing strength and corrosion resistance. One of the methods used for the production of such coated films is the PVD (Physical Vapour Deposition) process. However, electron and scanning electron microscopy analysis reveals the frequent occurrence of a complex columnar nanostructure of the deposited TiN film resulting from the specific nature of the PVD process. The morphology of such nanostructure is one of the main reasons for uncontrolled delamination and fracture observed in films during, e.g., stamping processes. Accurate investigation of film behavior during forming and exploitation conditions requires a series of very sophisticated laboratory experiments, which are time-consuming and expensive. Therefore, in this work, a new approach to the numerical analysis of the crack evolution of deposited films based on the digital material representation concept is proposed. A series of microstamping simulations were carried out as a case study to evaluate the model capabilities. The study proved that the model based on digital material representation can be used for reliable predictions of the local material behaviour of sheets with deposited complex films.

The structure of thin films and coatings is frequently complex due to the nature of deposition processes. It consists of columns with intercolumnar boundaries that are often precursors of crack initiation and propagation, which can lead to delamination of the film from the substrate. The simulation of the behaviour of thin film and coatings without considering their complex morphology presents a significant limitation in achieving reliable results. Therefore, to address this challenge, a set of approaches for generating a full-field digital representation of thin films/coatings for subsequent numerical studies was developed within the work. These algorithms are divided into three categories characterised by different levels of complexity. The first is based on image processing algorithms for directly mapping the exact morphology of films/coatings from experimental data. The second is based on the cellular automata and Monte Carlo algorithms, providing a statistically similar representation of films/coatings structures. Finally, the third uses physics-based modelling methods to replicate the deposition process of films/coatings on the substrate. The methodologies outlined in this work facilitate the preparation of digital morphologies of any complex deposited structure for subsequent incorporation into numerical simulations examining their behavior under processing and in-use conditions. This enables the use of numerical methods in the detailed investigation of deposited structures designed for practical applications in a wide range of industries, which is important from an ecological and economic point of view.

This article presents the results of research concerning a comprehensive analysis of the operation of tools used for forming ceramic roof tiles in the clay-based band extrusion process. The conducted studies demonstrated that key process parameters, such as extrusion pressure and the flow speed of the ceramic mass containing hard components, are crucial for the durability of the tools, significantly affecting their wear. The analysis of the formed mass revealed the presence of hard fractions, such as quartz, zircon, and garnet, which significantly contribute to tool abrasion. Among the tested hardening variants of NC11LV steel, the best results in terms of enhanced longevity were operational tools treated at 1020 °C and then tempered at 200 °C for two hours. These results were confirmed in both operational tests and the dry abrasion test, indicating high wear resistance. Additional hardening through nitriding further extended the tool’s lifespan. The greatest wear was observed in the tool made of Hardox 600 steel with an additional overlay weld, which was caused by improper welding techniques. Numerical modeling, particularly the mesh-free SPH approach, proved to be the most effective method for analyzing the ceramic mass extrusion process.

Determining the mechanical properties of thin films presents significant challenges due to their nanometer-scale thickness. The separation of thin films from their substrates for standard plastometric testing is often difficult, if not impossible, complicating the direct measurement of their properties. Consequently, nanoindentation tests, which involve using small indenters and analyzing force-displacement curves, are commonly employed to assess the mechanical properties of thin films. However, experimental methods alone may be insufficient for accurately determining these properties for such thin films. This paper proposes an approach that combines numerical modelling of nanoindentation tests with the finite element method and inverse analysis to determine the optimal material constants for the substrate and thin film. The study focuses on TiN thin films deposited on silicon and stainless steel substrates as case studies. Prior to extracting the properties of the thin films, a comprehensive numerical accuracy analysis of the nanoindentation model was conducted. This involved investigating the impact of the digital model on the accuracy of results, comparing 2D and 3D models to optimize computational efficiency, and analysing the effect of finite element mesh discretization. The critical importance of accurately representing the indenter shape for reliable results was also highlighted. Following model validation, a series of nanoindentation simulations were performed on silicon and subsequently on the TiN/Si structure, enabling the separate determination of material constants for the substrate and the TiN thin film. The procedure was then applied to the TiN/SS structure for verification. The findings demonstrate that this approach enables the determination of the as-deposited thin film material properties based solely on nanoindentation tests and a robust numerical model, and it can be extended to other thin films.

Predicting microstructure morphology evolution under hot forming conditions and determining final material properties are essential for optimizing metal-forming processes. Cellular Automata (CA) is a widely employed full-field method for modeling microstructure morphology changes during various metal-forming processes. However, at higher temperatures and under conditions of substantial microstructure evolution, the CA method encounters limitations related to computational domain geometry changes. The use of random cellular automata (RCA) offers a more realistic representation of this phenomenon, although it requires additional effort in algorithm optimization for acceptable execution times. This paper contributes to an overarching research effort focused on developing a discontinuous dynamic recrystallization model (DRX) by directly incorporating RCA into the finite element (FE) framework. Different mesh sizes and their impact on the quality of the results are analyzed, and the minimum number of elements that do not degrade the results in the CA model are selected. The investigation aims to enhance the practicality of the proposed model, striking a balance between realistic microstructure representation and computational efficiency.

Dynamic recrystallisation (DRX) is one of the fundamental phenomena in materials science, significantly impacting the microstructure and mechanical properties of components subjected to large plastic deformations. Experimental research on that topic carried out for a wide range of new metallic materials is often supported by computational materials science. A direct consideration and detailed understanding of this phenomenon are possible with a class of full-field numerical models based on the cellular automata (CA) method. However, the classical CA approach is based on a regular, fixed computational space and has limitations in capturing large deformations of the computational domain. Therefore, the main goal of the work is to develop and implement an alternative solution to overcome this limitation. The proposed solution is based on coupling the finite element (FE) method with the random cellular automata (RCA) approach. Such a model can directly consider the influence of geometrical changes in microstructure during large plastic deformation on recrystallisation progress. Details of the developed RCA DRX model assumptions and coupling issues with FE mesh are discussed. Particular attention is also paid to increasing model efficiency and robustness studies.

The classical approach to fracture simulation in a thin film for bioengineering applications neglects the under-lying complex morphology of the deposited layer, leading to inaccurate numerical predictions. That may carry high risks during product development and its further exploitation, especially in biomedical applications. Therefore, here, we demonstrate the new approach to numerical investigation of the fracture evolution in pulsed laser-deposited (PLD) titanium nitride (TiN) thin films under loading conditions based on the full-field model of layer columnar morphology. We use the TiN film deposited on the aluminium (Al) substrate as a case study. Based on the nanoindentation test, we first determine the flow stress characteristics of the Al substrate and TiN/ Al structure. An inverse analysis technique allowed us to precisely recalculate measured load-displacement values into the required stress-strain curve. Then, we developed a full-field model based on the digital material representation (DMR) concept for further investigation. The DMR was generated to replicate major morpho-logical features of the deposited thin film identified under transmission electron microscop (TEM). Finally, we incorporated the TiN/Al full-field model into the finite element analysis with a cohesive zone approach for local analysis of fracture behaviour. Inverse analysis based on the developed direct model and experimental mea-surements allowed us to identify the parameters of the fracture model. As a result, we proved that the full-field model based on the digital material representation concept could be used for reliable predictions of local fracture development along the morphological features of the deposited thin film.

The main objective of this work is to investigate the influence of the definition of dies type in the finite element simulation of the two-points incremental forming processes (TPIF). Particular attention is on determining the effect of assigning elastic properties for the 3D printed dies or considering fully rigid on the final results. During the research, three different shapes of dies were analyzed. Simulation results in the form of sheet thickness distributions and measured forces are presented for comparison purposes.

Development of the descriptors of the multiphase microstructure, which will allow comparing material's local fracture resistance, is the objective of the article. A hypothesis is made that local gradients of properties can realistically represent the tendency to the local fracture and can be an effective indicator for the stretch‐flangeability properties. A novel gradient evaluation algorithm was developed within the study. The algorithm calculates the distribution of gradients for the data given in the form of a cloud of points, independently of the source of these data. Two industrial grade dual‐phase (DP) and complex‐phase (CP) steels are produced from the same cast chemical composition and with the same processing route; however, different parameter setups are studied using a correlative microstructure characterization approach to supply data for gradients evaluation. Obtained electron backscattered diffraction maps are used to generate the representative volume elements and statistically similar representative volume elements, which are subjected to deformation and used to calculate the properties gradients theoretically. The high‐resolution hardness maps are used to directly obtain the hardness gradients. Both methods of gradients calculations are applied to the DP and CP microstructures and prove to be an effective and reliable method for the comparison of materials’ stretch‐flangeability.

The main objective of this work is to investigate the representativeness of the digital material representation (DMR) models of ferritic-pearlitic steel generated by the hybrid cellular automata (CA) / Monte Carlo (MC) algorithm. Particular attention is focused on determining the effect of the size of the digital representation model on its representativeness under deformation conditions simulated with the finite element (FE) framework. In addition, the effect of periodic and non-periodic boundary conditions on the deformation behaviour of DMR models is analysed. A dedicated buffer zone approach applied the periodic boundary conditions on non-periodic finite element models. The results of equivalent stresses and strains and their average values are used to evaluate the differences between the models’ predictions

The computer-aided development of the leveling technology for high-strength steel flat sheet products is the primary goal of the research. The roll leveler setups are evaluated from the final product point of view with an acceptable flatness level and stress state at the same time. First, a reliable hardening model is developed based on experimental and numerical investigation. The combined isotropic-kinematic model is selected to capture material behavior under cyclic loading conditions. The inverse analysis approach is used for the high-quality model parameters identification stage. Then the roll leveling process for a wide range of machine setups is simulated using a finite element model. Examples of results in the form of final flatness and stress distributions are presented within the work. As an outcome, a set of process parameters is identified that provides a good quality product for both investigated criteria.

Screens made of drawn and spot-welded stainless steel precise profile wires are widely used to separate particles from fluids during various industrial applications. Increased durability and surface quality of these products are critical in maximising their wear resistance and extending the screen service life. Therefore, the paper discusses the development of metal forming technology considering the surface quality and residual stress level of austenitic and lean-duplex steel profile wires for the production of high-quality industrial screens. It is shown that surface engineering driven by metal forming is a key factor in extending the life and performance of these products.

The work focuses on developing the complex digital shadow of the metallic material microstructure that can predict its evolution during metal forming operations. Therefore, such a digital shadow has to consider all major physical mechanisms influencing the particular investigated phenomenon. The motivation for the work is directly related to the development of modern metallic materials, often of multiphase nature, which leads to local heterogeneities influencing microstructure behavior and eventually macroscopic properties of the final product. The concept of the digital microstructure shadow, stages of the model development, and examples of practical applications to simulation of microstructure evolution are presented within the work. Capturing local heterogeneities that have a physical origin and eliminating numerical artifacts is particularly addressed. Obtained results demonstrate the capabilities of such a digital microstructure shadow approach in the numerical design of final product properties.

Herein, we evaluate the nanoindentation test capabilities in the determination of flow stress characteristics of the matrix material in porous sinters. The Distaloy AB sample with 15% porosity after the sintering operation is selected as a case study for the investigation. 2D and 3D imaging techniques are employed first to highlight difficulties in identifying reliable nano hardness measurement zones for further properties evaluation. Then, nanoindentation test results are acquired with Berkovich tip pressed under various loads at different locations in the sample. Systematic indentations in the quartz sample are used as a cleaning procedure to minimize the effect of the possible build-up around the indenter tip. The representative indentation load range is selected based on the extracted material characteristics. With that, the stress–strain response of the sinter matrix material is identified. The reliability of the determined flow stress curve is confirmed with the use of conical nanoindentation measurement results and finite element simulations. Obtained results show that it is possible to calculate reliable flow stress characteristics of the matrix in the porous samples, with the assumption that experiments under various loading conditions and from various locations in the matrix are performed. It is also pointed out that various indentation loads should be used to eliminate the influence of the pile-up or scale effects that affect the overall material response.

Numerical study of the influence of pulsed laser deposited TiN thin films' microstructure morphologies on strain heterogeneities during loading was the goal of this research. The investigation was based on the digital material representation (DMR) concept applied to replicate an investigated thin film's microstructure morphology. The physically based pulsed laser deposited model was implemented to recreate characteristic features of a thin film microstructure. The kinetic Monte Carlo (kMC) approach was the basis of the model in the first part of the work. The developed kMC algorithm was used to generate thin film's three-dimensional representation with its columnar morphology. Such a digital model was then validated with the experimental data from metallographic analysis of laboratory deposited TiN(100)/Si. In the second part of the research, the kMC generated DMR model of thin film was incorporated into the finite element (FE) simulation. The 3D film's morphology was discretized with conforming finite element mesh, and then incorporated as a microscale model into the macroscale finite element simulation of nanoindentation test. Such a multiscale model was finally used to evaluate the development of local deformation heterogeneities associated with the underlying microstructure morphology. In this part, the capabilities of the proposed approach were clearly highlighted.