Optimization and validation of a dislocation density based constitutive model for as-cast Mg-9%Al-1%Zn

A dislocation density-based constitutive model, including effects of microstructure scale and temperature, was calibrated to predict flow stress of an as-cast AZ91D (Mg-9%Al-1%Zn) alloy. Tensile stress-strain data, for strain rates from le up to 10(-1) s(-1) and temperatures from room temperature up to 190 degrees C were used for model calibration. The used model accounts for the interaction of various microstructure features with dislocations and thereby on the plastic properties. It was shown that the Secondary Dendrite Arm Spacing (SDAS) size was appropriate as an initial characteristic microstructural scale input to the model. However, as strain increased the influence of subcells size and total dislocation density dominated the flow stress. The calibrated temperature dependent parameters were validated through a correlation between microstructure and the physics of the deforming alloy. The model was validated by comparison with dislocation density obtained by using Electron Backscattered Diffraction (EBSD) technique.