Faisal Qayyum- Ph.D. Multi-scale and multi-physics computational mechanics of multi-phase metallic materials
- Post Doctoral Research Associate at TU Bergakademie Freiberg
Faisal Qayyum
- Ph.D. Multi-scale and multi-physics computational mechanics of multi-phase metallic materials
- Post Doctoral Research Associate at TU Bergakademie Freiberg
Microstructurally informed modeling of the structure-property relationships in multi-phase metallic materials
About
66
Publications
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Introduction
The focus of my current work the ongoing studies is to:
- Reduce dependence of metal and forming industry on critical alloying elements
- Shift processes to clean and sustainable energy sources
- Improve process efficiency and reduce energy requirements
- Directly and indirectly reduce carbon foot print of the production processes
- While doing all of above, keep the mechanical properties and service life of the components same or improve them more for targeted applications.
Current institution
Additional affiliations
January 2017 - present
Position
- Research Associate
Description
- Currently, I am working on the following: - Modeling the deformation behavior of TRIP Steel composites in my doctoral thesis. - Working as a research associate in a DFG funded project related to the correlation of phase morphology and flow behavior of spheroidization steels. - Application-oriented use of advanced crystal plasticiy based tools for the identification of structure-property relationship in multi-phase steels
September 2014 - December 2016
September 2014 - October 2015
Publications
Publications (66)
In this work, ceramic particle and metal matrix interfacial delamination in transformation-induced plasticity steel composite reinforced with magnesium partially stabilized zirconia particles is investigated using a parametric modeling approach. The global behavior of the composite is modeled using elastic and Johnson-Cook plasticity models for the...
This collection of papers entitled "Process-structure–property relationship of lightweight metallic materials" brings together a selection of advanced research papers that focus on the multifaceted relationships between processing methods, microstructural evolution, and the resulting thermomechanical properties of lightweight metallic materials. Un...
This study investigates tensile deformation, damage analysis, and the effect of microtexture on a 10 % vol. zirconia particle-reinforced TRIP steel composite. In situ tensile tests and simulations were conducted, with sequential SEM images captured during tensile loading tests and electron backscatter diffraction (EBSD) providing initial crystal or...
This study investigates deformation, interfacial, and particle damage in a magnesium-partially stabilized zirconia (Mg-PSZ) particle-reinforced transformation-induced plasticity (TRIP) steel composite using SEM in situ tensile tests and finite element simulations. The simulation models employ an elastic model for ceramic particles and a Johnson-Coo...
In this study, we quantitatively investigate the impact of 1.4 wt.% chromium and 1.4 wt.% molybdenum additions on pearlitic microstructure characteristics in 1 wt.% carbon steels. The study was carried out using a combination of experimental methods and phase field simulations. We utilized MatCalc v5.51 and JMatPro v12 to predict transformation beh...
In this work, the microstructural deformation and damage mechanisms of TRIP steel metal matrix composites (MMCs) reinforced with Magnesia Partially Stabilized Zirconia (Mg-PSZ) particles are investigated by employing in situ tensile testing within a scanning electron microscope chamber, complemented by digital image correlation and advanced image p...
This research provides a comprehensive analysis of the texture and temperature dependent deformation behavior of the aluminum alloy AA6082. The study is performed using a combination of experimental deformation tests and computational simulations based on a crystal plasticity (CP) framework. The primary objective is to identify the critical influen...
Magnesium partially stabilized zirconia (Mg-PSZ) particle reinforced transformation induced plasticity (TRIP) steel-based metal matrix composites (MMCs) comprise ductile steel matrix and hard ceramic reinforcements. In these materials, both phases might undergo a martensitic transformation during deformation. The overall deformation behavior depend...
In this study, the behavior of MnS particles in a steel matrix is investigated through in situ tensile testing and digital image correlation (DIC) analysis. The goal of this research is to understand the mechanical behavior of MnS inclusions based on their position in the steel matrix. To accomplish this, micro-dog bone-shaped samples are prepared,...
A process map is an intelligent way of visualizing material deformation behavior under hot working conditions by encompassing the activation and deactivation of different local mechanisms. Process maps are used by engineers to optimize temperature and strain rate conditions appropriate for the highly efficient hot workability of materials. Although...
This study aims to investigate the effect of chromium and molybdenum on the formation of pearlitic microstructure in 1% carbon steels. To obtain experimental data, 12mm wires of one benchmark (Fe-1C) and two trial alloys (Fe-1C-1.5Cr and Fe-1C 1.5Mo) are manufactured in-house by casting and hot caliber rolling. These wires are homogenized at a temp...
In this study, the effect of the energy release rate on the transformation-induced plasticity (TRIP) steel composite reinforced with 5 vol% ceramic particles is determined using the crystal plasticity simulation of the coupled brittle-ductile damage model and validated by experimental results. A miniature dog bone tensile sample is subjected to an...
In this work, two simulation models were used to investigate the local deformation and damage behavior of partially stabilized zirconia-reinforced metastable austenitic steel composites and validated by experimental results. An in situ quasi-static tensile test on a miniature dog bone sample is performed under an electron microscope up to 6.4% true...
![A single-phase isotropic RVE [14] is shown, where each color represents...](publication/366399192/figure/fig2/AS:11431281387577448@1745127384856/A-single-phase-isotropic-RVE-14-is-shown-where-each-color-represents-a-different-grain_Q320.jpg)
In this study, we developed hot working process maps for incompressible TRIP steel composites with 0%, 5%, 10%, and 20% zirconia particles using crystal plasticity-based numerical simulations. Experimentally recorded material flow curves were used to calibrate material model parameters for TRIP steel and zirconia. The fitted material models were us...
The Special Issue on 'Crystal Plasticity in Forming Technologies' is a collection of 11 original articles dedicated to theoretical and experimental research that provides new insights and practical findings in topics related to crystal plasticity. Advancements in materials science have led to the development of complex materials for targeted applic...
The TRIP Steel matrix-based zirconia particle composites have been shown to depict significantly higher strength and ductility due to strain-based phase transformation during deformation. The composites’ macroscopic deformation depends on the microscopic behavior of each phase. Given an applied loading history, the local elastic and plastic anisotr...
Crystal plasticity-based numerical simulations help understand the local deformation behavior of multiphase materials. It is known that in full phase simulations, the local 2-dimensional (2D) representative volume elements (RVEs) results are distinctly different from 3-dimensional (3D) RVEs. In this work, the difference in the results of 2D and 3D...
Spheroidized steel microstructure presents a remarkable combination of strength and ductility suitable for cold forming applications. As the commercial spheroidization process consumes a significant amount of time and energy, therefore, suitable degree of spheroidization for specific material must be established to get the desired mechanical proper...
This work investigates a ferrite matrix with multiple non-metallic inclusions to evaluate their influence on the global and local deformation and damage behavior of modified 16MnCrS5 steel. For this purpose, appropriate specimens are prepared and polished. The EBSD technique is used to record local phase and orientation data, then analyze and ident...
This study analyses the effect of martensite grain size and its volume fraction in dual-phase (DP) steel on (1) the formability limit, (2) average global behavior under different loading conditions, and (3) damage initiation. The virtual RVEs (Representative Volume Elements) were constructed using DREAM.3D software with a variation of microstructur...
Herein, micromechanical simulations for three different states of spheroidized steel (C45EC) are conducted under quasi‐static tensile loading based on the actual texture and crystallographic orientation from electron backscatter diffraction (EBSD) data. Data denoising is conducted with MTex (open‐source Toolbox with MATLAB) for cleaning up the EBSD...
This research uses EBSD data of two thermo-mechanically processed medium carbon (C45EC) steel samples to simulate micromechanical deformation and damage behavior. Two samples with 83% and 97% spheroidization degrees are subjected to virtual monotonic quasi-static tensile loading. The ferrite phase is assigned already reported elastic and plastic pa...
The mechanical behavior of newly developed composite materials is dependent on several underlying microstructural phenomena. In this research, a periodic 2D geometry of cast X8CrMnNi16-6-6 steel and 10% zirconia composite is virtually constructed by adopting microstructural attributes from literature. A physics-based crystal plasticity model with d...
The influence of microstructural attributes of crystalline material on its overall mechanical properties is of vital importance to get desired plasticity of a component. Varying grain morphology and distribution of the multi-phase steels can pose plastic flow challenges during cold forming. The spheroidized medium carbon steels obtained by reformin...
In this study, DAMASK was used to model and elucidate the microstructural deformation behavior of sintered X3CrMnNi16-7-6 TRIP steel. The recently developed TRIP-TWIP material model was used within the DAMASK framework. Material optimization was performed using the least computationally expensive method, which yielded the desired results. The physi...
Featured Application
The current work is a step towards developing a virtual laboratory for engineering materials for targeted applications using a microstructurally informed crystal plasticity-based numerical simulation model.
Abstract
Physics-based and phenomenological crystal plasticity numerical simulations provide an opportunity to develop mi...
In this research, the effect of 2D and 3D Representative Volume Element (RVE) on the ductile damage behavior in single-phase (only ferrite) and dual-phase (ferrite and martensite) steels is analyzed. Physical and fitting parameters of the constitutive model for bcc-ferrite and bcc-martensite phases are adapted from the already published work. Cryst...
In this research, percentages of nickel as austenizer and chromium as ferritizer, in the molten metal pool of SS304L weldments are varied to analyze the effect on the produced delta ferrites morphology and volume. The resulting localized precipitation of delta ferrite and its effect on the fatigue crack propagation rate of the material are examined...
Herein, micromechanical material deformation behavior of medium carbon steel—with varying cementite particle size and distribution—under monotonic tensile load is modeled. The statistical phase morphology data are collected from the microscopy images of 83% spheroidized C45EC steel. Virtual microstructures for nine different cases are constructed u...
From the last few decades, the piezoelectric materials are playing a vital role in the field of energy harvesting because of their capability to convert mechanical energy from the surroundings into useful electrical energy. In this research, the performance of the piezoelec-tric energy harvester (PEH) in cantilever configuration with varying length...
Crystal plasticity simulations help to understand the local deformation behavior of multi-phase materials based on the microstructural attributes. The results of such simulations are mainly dependent on the Representative Volume Element (RVE) size and composition. The effect of RVE thickness on the changing global and local stress and strain is ana...
In this research, a detailed multi-physics study has been carried out by numerically simulating a solid fractured gun barrel for 20 thermo-mechanical cycles. The numerical model is based on thermal effects, mechanical stress fields and fatigue crack mechanics. Elastic-plastic material data of modified AISI 4340 at temperatures ranging from 25 to 12...
The interaction of mechanical components experiencing relative movements and cyclic loads in a corrosive environment is known as fretting corrosion or tribocorrosion. In the current work, the mechanism of crack initiation and propagation in dovetail slots of Ti6Al4V samples (in contact with carbide rods) under fretting corrosion conditions was inve...
To improve the oxidation resistance of carbon/carbon composites at high temperatures (>1770 K), they were coated with MoSi 2-Si 3 N 4 /SiC. The slurry and pack cementation methods were adopted to deposit the inner SiC layer and outer MoSi 2-Si 3 N 4 layer. The phase composition, microstructure, and elemental distributions in the coating were analyz...
In the continuously advancing technological world, there is an increasing demand for materials with desired material properties. High strength and formability materials are in demand in the automotive and aerospace industry. Metal matrix-based composited provide an excellent solution for high energy absorbing structural applications. The mechanical...
In this study, DAMASK was used to model and elucidate the microstructural deformation behavior of sintered X3CrMnNi16-7-6 TRIP steel. The recently developed TRIP-TWIP material model was used within the DAMASK framework. Material optimization was performed using the least computationally expensive method, which yielded the desired results. The physi...
A Transformation-Induced Plasticity (TRIP) steel matrix reinforced with magnesium-partially stabilized zirconia (Mg-PSZ) particles depicts a superior energy absorbing capacity during deformation. In this research, the TRIP/TWIP material model already developed in the framework of the Düsseldorf Advanced Material Simulation Kit (DAMASK) is tuned for...
Thermal fatigue is a material failure phenomenon that occurs when a component is subjected to thermal fluctuations. After more than a decade of research on thermal fatigue cracking in nuclear reactor components the science is yet incomplete. In this research a finite element based numerical simulation model has been developed using a commercial sof...
Aluminum alloys are widely used for fabrication of aircraft, civil structures, and space vehicles. Fatigue life consideration of a material is the most important design criteria in many such critical applications. In this research work, a widely used Aluminum alloy AA2219-T87 was TIG welded using AA2319 as a filler material. The effect of natural a...
Electric Discharge Machining (EDM) is widely used for manufacturing complex metal parts. The machining parameters like dielectric fluid, electrode material, current, voltage and pulse rate during EDM are controlled to obtain desired Material Removal Rate (MRR), and it also affects the surface morphology of manufactured components. In this research,...
Sulphur is added to steels for improving the machinability of the components, yet, it is believed that it reduces the formability of alloys. In this research, the effect of varying sulphur content from 0.008% for the 16MnCr5 steel to 0.03% for the steel 16MnCrS5 on formability under different loading conditions has been investigated. Different form...
Effect of commercial grade chrome plating on the fretting fatigue life of AISI D2 is investigated using recently developed inverted pin-in-dovetail configuration fixture. Chrome plated and non-plated specimens having hardness of 40, 43, 52, 57 and 62 HRC were tested. All samples were tested at 7.5 kN tension-tension axial load (R = 0.1) at a consta...
Addition of Sulfur to iron alloys improves the machinability of the components but reduces the formability. In this research, effect of varying Sulfur content from 0.008% to 0.03% in 16MnCr5 alloy steel on the formability of this steel grade by employing different formability tests is carried out. Tensile testing, transverse extrusion testing, expa...
Piezoelectric materials are widely used as smart structure in various aerospace applications as they can generate voltage, store charge and drive microelectronics directly because of its ability to sense, actuate and harvest energy. It is a well known phenomenon in terms of the linear electromechanical interaction between mechanical and electrical...
Effect of solidification rate on crack tip plastic zone size at various crack lengths was calculated analytically and numerically by simplified Sih's and Irwin's models, respectively. Influence of plastic zone size is explained in terms of COD and elastic stress intensity factor within valid range of small scale yielding approximation. Up to plasti...
Purpose
The fabrication and characterization of a hydrogel-based conductometric sensor have been carried out. The purpose of this research is to fabricate a small robust hydrogel-based conductometric sensor for real-time monitoring of pH in the physiological range.
Design/methodology/approach
A pH-responsive Chitosan/Gelatin composite hydrogel h...
Carbon fiber reinforced aluminum laminates (CARALL) are one of the aluminum based Fiber metal laminates (FMLs) which, due to their high strength to weight ratio and good impact resistance are greatly replacing aluminum alloys in aircraft structures. In this research work, interlaminate shear strength of Vacuum assisted resin transfer molding (VARTM...
The effect of discharge current and pulse duration during the electric discharge machining of Aluminum alloy 6061 T6 is studied using copper electrode with paraffin oil and distilled water as a dielectric medium. The electric discharge machined surface is characterized by surface roughness (Ra), crack intensity, and average white layer thickness (A...
Fibre metal laminates (FMLs) are being used to manufacture many structural components in aerospace industry because of their very high strength to weight ratios, yet the exact model for estimating fatigue crack propagation in FMLs cannot be developed because of many variable parameters affecting it. In this research, tensile strength, fatigue life...
Thermal fatigue loading is a major failure mechanism in machinery operating at high temperatures. Exact numerical modeling of this phenomena helps in better understanding of crack propagation governing factors, which eventually helps in avoiding catastrophic failures. In this research numerical simulation model for crack propagation in a 3D wedge o...
![Table 2 . Properties of PZT-4A [19]](profile/Muhammad-Ali-215/publication/313675462/figure/tbl2/AS:613910386327602@1523379050892/Properties-of-PZT-4A-19_Q320.jpg)
Piezoelectricity is the capability of a piezoelectric material to change mechanical energy into electrical energy. The determination of electrical and mechanical properties plays a significant role in characterizing the piezoelectric material. The energy losses characteristics of piezoelectric material can be described by mechanical quality factor....
The design and fabrication of a wound healing device for chronic wounds, with multiple functions for controlled drug delivery and exudate removal, has been described in the current study. The structural features have been machined and modified through laser cutting in a biocompatible polymer cast. Miniaturized versions of electronically actuated (l...
For achieving additional benefits and improving the material characteristics two or more materials are often combined together in the form of composites. Composites are important because of their light weight, high strength and flexibility of design. Composite materials provide various advantages based on their particulate or fibrous nature and on...
Energy harvesting is the process of attaining energy from the external sources and transforming it into usable electrical energy. An analytical model of piezoelectric energy harvester has been developed to determine the output voltage across an electrical circuit when it is forced to undergo a base excitation. This model gives an easy approach to d...
High deep draw ratio of metal sheets is often required in industry to produce complex structural components and is considered to be problematic beyond a draw ratio of 1.7. In addition, anisotropy of material plays a great role in the final form of deep drawn products. In this research AISI SS304 L high draw ratio deep drawing (HDR) cups have been d...
Alumina ceramics having small grain size and high density yield good mechanical properties, which are required in most mechanical applications. Two Step Sintering (TSS) is used to develop dense alumina ceramics. In this research work the effect of sintering temperatures on microstructure and density of the alumina specimens developed by using TSS h...
Thermal fatigue is one of the key reasons of material failure in components which are exposed to high temperature cycles. Prediction of crack initiation site and crack propagation speed during thermal cycling helps us predict the life of a component in service. In this research numerical simulation of crack propagation due to thermal cycling on a c...
Rubber forming has become an important tool to manufacture high precision and complex tube parts, but as the part complexity and the choice of metal increases the calculations required to accurately determine the final shape become increasingly complex. The accuracy of the final shape of the product depends upon the different parameters, like mater...
This paper presents the results of fretting fatigue tests carried out on Ti6Al4V sheet specimens in contact with
carbide rod in a cylinder-on-flat contact configuration. A new methodology of carrying out fretting fatigue
experiments is proposed and successfully implemented using a pin-in-dovetail and pin-in-hole configuration.
The advantage of this...
Compact tension (CT) specimen is used to investigate the behavior of fatigue crack growth rate (FCGR) of preheat-treated tungsten inert gas (TIG) welded aluminum alloy (AA2219-T87) on MTS-810. Filler metal used for weld is AA2319. ASTM E399 standard provides a method to convert crack mouth opening displacement (CMOD) data to crack length in CT spec...
![Fig. 2a: Flow of material through ECAP die [1]](profile/Faisal-Qayyum-2/publication/287998687/figure/fig9/AS:670525382729739@1536877117353/a-Flow-of-material-through-ECAP-die-1_Q320.jpg)
This paper presents a novel model for plastic shear strain calculation in the Equal Channel Angular Pressing (ECAP). The model is particularly formulated to furnish for the elastic recovery after extrusion. Due to high elastic recovery after plastic deformation in polymers, the behavior of Teflon and Nylon is investigated at different temperatures...
In industrial practice it takes multiple steps to produce complex shaped sheet metal parts of good tolerances and better surface finish. Sheet hydroforming can be useful process to produce complex shaped parts of better finish and tolerances, while keeping the production rate faster and cheaper. Yet many parts are still not manufactured by this pro...
Thermomechanical stresses play an important role in defining the life of the work roll used in hot
rolling process. In this research temperature dependent mechanical properties of cartridge brass
are determined experimentally using high temperature compression tests at different temperatures
and strain rates. Real life measurements are made from a...
Currently whole world and specially Pakistan is facing acute energy crisis. The most important problem in today’s date is to overcome the energy crisis. The costs of oil, coal and other fuels are increasing day by day; also these energy recourses are increasing greenhouse gasses in environment. Considering Pakistan specifically, we need very cheap,...
Questions
Questions (6)
Hello,
I am currently using Dream3D to construct multi-phase Representative Volume Elements (RVEs) and would like to know if it is possible to create RVEs with varying grain sizes. Specifically, I am interested in models where finer grains are located near the surfaces and coarser grains are in the center, or where grain size increases linearly from one side to the other.
Additionally, I am exploring the concept of defining grain growth in a selected region, allowing grains to grow for a certain number of iterations based on Voronoi tessellation.
Any guidance or resources on this matter would be greatly appreciated.
