US-12625126-B2 - Method of modelling of a material

Abstract

A method of predicting a mechanical property of a material subjected to a transformation process is disclosed including a modelling step, wherein a microstructural model of the material is created, a simulation step, wherein the microstructural model of the material is virtually subjected to a transformation process (such as a heat treatment process), a generation step, wherein at least one micro-scale model configured for predicting at least one mechanical property of the material is generated, and a virtual mechanical characterisation, wherein at least one mechanical property of the material is predicted. Advantageously, by implementing this method it has been found that lead times incurred when developing new material transformation processes can be reduced.

Inventors

• Rohan ROY
• Trupti KULKARNI

Assignees

• AIRBUS SAS

Dates

Publication Date

20260512

Application Date

20211027

Priority Date

20201130

Claims (20)

1. 1 . A computer-implemented method of predicting a mechanical property of a material subjected to a microstructural transformation, the method comprising: a modelling step, wherein a microstructural model of the material is created for predicting a microstructural evolution of the material upon subjection to the microstructural transformation; a simulation step, wherein the microstructural model of the material created during the modelling step is virtually subjected to the microstructural transformation; a generation step, wherein at least one micro-scale model is generated, and wherein the at least one micro-scale model is configured for predicting at least one mechanical property of the material based on the microstructural model after it has been virtually subjected to the microstructural transformation; a characterising step, wherein a virtual characterisation is performed on the microstructural model using the at least one micro-scale model generated during the generation step, so as to predict the at least one mechanical property of the material after it has been virtually subjected to the microstructural transformation; performing a microstructural transformation process on a physical sample of the material, wherein the transformation process is based on the simulated microstructural transformation from the simulation step, and wherein using the transformed sample as a component; performing validation processes at each step of the method; and feeding back the results of these validation processes into the model in order to help better ensure the accuracy of the model.
2. 2 . The method according to claim 1 , wherein the at least one micro-scale model comprises a crystal plasticity simulation model and wherein the virtual characterisation comprises a crystal plasticity simulation.
3. 3 . The method according to claim 1 , wherein the microstructural model comprises a multi-phase field model.
4. 4 . The method according to claim 1 , wherein the microstructural transformation simulated as part of the simulation step comprises a heat treatment process.
5. 5 . The method according to claim 1 , wherein the microstructural transformation simulated as part of the simulation step comprises a thermo-mechanical process.
6. 6 . The method according to claim 1 , wherein the microstructural model is created based on image data.
7. 7 . The method according to claim 6 , wherein the image data is obtained via at least one of X-Ray Diffraction; Scanning Electron Microscope (SEM) microscopy; Transmission Electron Microscope (TEM) microscopy and/or Electron Back Scattering.
8. 8 . The method according to claim 6 , wherein the image data comprises a plurality of images, wherein the modelling step comprises estimating a probability distribution for at least one of a grain size, a grain orientation, a grain shape and/or a percentage of alpha and beta phase material based on the image data, and wherein a simulation performed as part of the simulation step comprises performing a probabilistic simulation using the probability distribution estimated during the modelling step.
9. 9 . The method according to claim 6 , wherein the image data comprises a plurality of images and wherein the image data is obtained from at least two different viewpoints.
10. 10 . The method according to claim 1 , wherein the image data comprises a plurality of images, wherein the modelling step comprises extracting an upper and/or lower bound of at least one of a grain size, a grain orientation, a grain shape and/or a percentage of alpha and beta phase material from the image data, and wherein a simulation performed as part of the simulation step is performed using the upper and/or lower bound data extracted during the modelling step.
11. 11 . The method according to claim 1 , wherein the simulation step comprises simulating effects of the microstructural transformation on at least one of a grain size and/or a grain density of the microstructural model.
12. 12 . The method according to claim 1 , wherein the characterising step comprises predicting at least one of a tensile strength, a compressive strength, a plasticity and/or a fracture toughness of the material virtually subjected to the microstructural transformation.
13. 13 . The method according to claim 1 , wherein the method further comprises: a characterisation validation step, wherein a mechanical characterisation simulated using the at least one micro-scale model is physically performed on a sample of the material; a second comparison step, wherein the at least one mechanical property of the material determined during the characterisation validation step are compared to the at least one mechanical property of the material predicted via the virtual characterisation; and a second feedback step, wherein the at least one micro-scale model is adjusted based upon the results of the second comparison step.
14. 14 . The method according to claim 1 , wherein the material is an additively manufactured material, and wherein the method further comprises, prior to the modelling step, a solidification modelling step wherein solidification of the material during the additive manufacturing process is simulated.
15. 15 . The method according to claim 14 , wherein the additive manufacturing process is one of Electron Beam Melting, Wire Feed Melting and/or Selective Laser Sintering.
16. 16 . The method according to claim 14 , wherein the simulation performed as part of the solidification modelling step is performed using a multi-phase field model.
17. 17 . The method according to claim 1 , wherein the material is an alloy material, preferably wherein the alloy material is a titanium-based alloy material and most preferably wherein the titanium-based alloy material is a metastable or near beta titanium-alloy material.
18. 18 . The method according to claim 17 , wherein the alloy material is one of: Ti-17, Ti-5553, Ti-35Nb-7Zr-5Ta, Ti-10-2-3, Ti-35Nb-5Ta-7Zr, Ti-29Nb-13Ta-4.6Zr, Ti-15V-3Cr-3Al-3Sn, Ti-15Mo-3Nb-3Al-0.2Si, Ti-15Mo, Ti-3Al-8V-6Cr-4Mo-4Zr, Ti-12Mo-6Zr-2Fe or Ti-13V-11Cr-3Al.
19. 19 . The method according to claim 17 , wherein the simulation step comprises virtually heating the microstructural model to a temperature either above or below a beta transus temperature of the material.
20. 20 . A system for predicting a mechanical property of a material comprising a computer configured to perform: a modelling step, wherein a microstructural model of the material is created for predicting a microstructural evolution of the material upon subjection to a microstructural transformation; a simulation step, wherein the microstructural model of the material created during the modelling step is virtually subjected to the microstructural transformation; a generation step, wherein at least one micro-scale model configured for predicting at least one mechanical property of the material based on the microstructural model is generated; a characterising step, wherein a virtual characterisation is performed on the microstructural model using the at least one micro-scale model generated during the generation step, so as to predict the at least one mechanical property of the material virtually subjected to the microstructural transformation; performing a microstructural transformation process on a physical sample of the material, wherein the transformation process is based on the simulated microstructural transformation from the simulation step, and wherein using the transformed sample as a component; performing validation processes at each step of the method; and feeding back the results of these validation processes into the model in order to help better ensure the accuracy of the model.

Description

CROSS RELATED APPLICATION This application claims priority to India Patent Application 202011052043, filed Nov. 30, 2020, the entire contents of which is hereby incorporated by reference. FIELD OF THE INVENTION The present invention relates to a method of predicting a mechanical property of a material subjected to a microstructural transformation, a computer-readable medium for executing said method, a component obtainable via a microstructural transformation based upon said method and a system for performing said method. BACKGROUND OF THE INVENTION The development of new materials processes, particularly those proposed for use in safety-critical applications, can be an extremely costly and time-consuming exercise. In fact, the development of new materials processes requires extensive experimentation and laboratory time for determining how various compositions respond to different processing conditions and for optimising process parameters based on the results of experimentation, typically using trail-and-error based methodologies. Furthermore, once a desirable set of parameters has been achieved, there is a further need to validate said results which further increases the lead time and costs incurred when developing such processes. It is therefore the aim of the present invention to provide a means for reducing the laboratory time (and associated costs) incurred when developing and optimising new materials processes. SUMMARY OF THE INVENTION According to a first aspect of the claimed invention, there is provided a method of predicting a mechanical property of a material subjected to a microstructural transformation, the method comprising a modelling step, wherein a microstructural model of the material is created for predicting the microstructural evolution of the material upon subjection to a microstructural transformation, a simulation step, wherein the microstructural model of the material created during the modelling step is virtually subjected to a microstructural transformation, a generation step, wherein at least one micro-scale model configured for predicting at least one mechanical property of the material based on the microstructural model is generated and a characterising step, wherein a virtual characterisation is performed on the microstructural model using the at least one micro-scale model generated during the generation step, so as to predict at least one mechanical property of the material virtually subjected to the microstructural transformation. The at least one micro-scale model may be a crystal plasticity simulation model. The virtual characterisation may be a crystal plasticity simulation. The microstructural model may be a multi-phase field model. The microstructural transformation simulated as part of the simulation step may be a heat treatment process. The microstructural transformation simulated as part of the simulation step may be a thermo-mechanical process. The microstructural model is created based on image data. The image data may be obtained via at least one of X-Ray Diffraction; Scanning Electron Microscope (SEM) microscopy; Transmission Electron Microscope (TEM) microscopy and/or Electron Back Scattering. The image data may comprise a plurality of images. The modelling step may comprise estimating a probability distribution for at least one of a grain size, a grain orientation, a grain shape and/or a percentage of alpha and beta phase material based on the image data. The simulation performed as part of the simulation step may comprise performing a probabilistic simulation using the probability distribution estimated during the modelling step. The image data may be obtained from at least two different viewpoints. The modelling step may comprise extracting an upper and/or lower bound of at least one of a grain size, a grain orientation, a grain shape and/or a percentage of alpha and beta phase material from the image data. The simulation performed as part of the simulation step may be performed using the upper and/or lower bound data extracted during the modelling step. The simulation step may comprise simulating the effects of the microstructural transformation on at least one of a grain size and/or a grain density of the microstructural model. The characterising step may comprise predicting at least one of a tensile strength, a compressive strength, a plasticity and/or a fracture toughness of the material virtually subjected to the microstructural transformation. The method may comprise a simulation validation step, wherein the microstructural transformation simulated in the simulation step is physically performed on a sample of the material, a first comparison step, wherein the microstructure observed following the simulation validation step is compared to the microstructure predicted during the simulation step and a first feedback step, wherein the microstructural model is adjusted based upon the results of the first comparison step. The method may comprise a character