Novel miniature in situ hole expansion test coupled with microscopic digital image correlation

The hole expansion ratio (HER) test is used to determine the stretch-flangeability of materials. Standard HER tests are performed on specimens sized a few tens of centimeters, termed macro-HER tests. This leads to significant material wastage due to the destructive nature of the tests. No information at the microstructure length scale is obtained, and the results suffer from user uncertainty in the identification of the through-thickness crack. This paper presents a novel miniature HER setup (termed micro-HER test), in which miniature specimens are tested inside a scanning electron microscope (SEM). The deformation is imaged from the top using the secondary electron detector installed in the SEM, coupled with the digital image correlation (DIC) technique, allowing for measurement of full field strains at the microstructural scale and identifying their deformation/fracture mechanisms. As a case study, six different steel grades were tested to measure their micro-HER values and compare them with the corresponding macro-HER values. The latter were found to be higher for the more ductile grades of steel. Late detection of through-thickness cracks and thicker samples leading to a higher volume of plastic deformation could contribute to this overestimation of values in macro-HER tests. DIC results from micro-HER tests on a ferrite–martensite (10% volume fraction) dual-phase steel showed high magnitudes of strain localization at the ferrite–martensite interfacial regions, indicating that such interfaces might be hotspots for failure under triaxial stress states. The challenges and errors associated with the measurements are also discussed.