PSI - Issue 68

ScienceDirect Structural Integrity Procedia 00 (2025) 000–000 Structural Integrity Procedia 00 (2025) 000–000 Available online at www.sciencedirect.com Available online at www.sciencedirect.com ScienceDirect Available online at www.sciencedirect.com ScienceDirect

www.elsevier.com/locate/procedia www.elsevier.com/locate/procedia

Procedia Structural Integrity 68 (2025) 1196–1202

European Conference on Fracture 2024 Development of a Damage-dependent Modified Material Model for Enhanced Description of Transient Material Behavior T. Korschinsky a* , B. Möller a , M. Kiel a , M. Hecht b a Fraunhofer, Institute for Structural Durability and System Reliability LBF, Bartningstraße 47, 64289 Darmstadt, Germany b Technical University of Darmstadt, Research Group System Reliability, Adaptive Structures, and Machine Acoustics SAM, Otto-Berndt-Straße 2, 64287 Darmstadt, Germany Abstract The growing popularity of electromobility is opening up new fields of application for various materials. For example, the aluminum alloy EN AW-1050A H24 is now of greater interest due to its good conductive properties. As a result, the material behavior of EN AW-1050A H24 must be accurately understood and described to properly assess fatigue life. To describe the cyclic material behavior of EN AW-1050A H24 special consideration should be given to the non-stabilizing cyclic softening. That leads to a significant mismatch of the experimental and simulated hysteresis loops using the Chaboche combined hardening model. In this study a new, Damage-dependent Modified Material Model is developed to fix this mismatch by calibrating the kinematic hardening parameters on experimental data in dependence to damage. As a result, the simulated hysteresis loops can precisely map the experimentally determined cyclic material behavior even without cyclic stabilization. © 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ECF24 organizers Keywords: Chaboche; Material model; EN AW-1050A H24; Softening; Hardening 1. Introduction For an efficient use of resources and a high system reliability of EV batteries the mechanical fatigue behavior of the components in a battery system needs to be addressed properly. One of the challenging components is the cell contacting system that is made from thin sheet metal of EN AW-1050A H24, which is commercially pure aluminum. Furthermore, the cell contacting system has a complex geometry with European Conference on Fracture 2024 Development of a Damage-dependent Modified Material Model for Enhanced Description of Transient Material Behavior T. Korschinsky a* , B. Möller a , M. Kiel a , M. Hecht b a Fraunhofer, Institute for Structural Durability and System Reliability LBF, Bartningstraße 47, 64289 Darmstadt, Germany b Technical University of Darmstadt, Research Group System Reliability, Adaptive Structures, and Machine Acoustics SAM, Otto-Berndt-Straße 2, 64287 Darmstadt, Germany Abstract The growing popularity of electromobility is opening up new fields of application for various materials. For example, the aluminum alloy EN AW-1050A H24 is now of greater interest due to its good conductive properties. As a result, the material behavior of EN AW-1050A H24 must be accurately understood and described to properly assess fatigue life. To describe the cyclic material behavior of EN AW-1050A H24 special consideration should be given to the non-stabilizing cyclic softening. That leads to a significant mismatch of the experimental and simulated hysteresis loops using the Chaboche combined hardening model. In this study a new, Damage-dependent Modified Material Model is developed to fix this mismatch by calibrating the kinematic hardening parameters on experimental data in dependence to damage. As a result, the simulated hysteresis loops can precisely map the experimentally determined cyclic material behavior even without cyclic stabilization. © 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ECF24 organizers Keywords: Chaboche; Material model; EN AW-1050A H24; Softening; Hardening 1. Introduction For an efficient use of resources and a high system reliability of EV batteries the mechanical fatigue behavior of the components in a battery system needs to be addressed properly. One of the challenging components is the cell contacting system that is made from thin sheet metal of EN AW-1050A H24, which is commercially pure aluminum. Furthermore, the cell contacting system has a complex geometry with © 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ECF24 organizers

* Corresponding author. Tel.: +49-6151-705-658. E-mail address: tim.korschinsky@lbf.fraunhofer.de * Corresponding author. Tel.: +49-6151-705-658. E-mail address: tim.korschinsky@lbf.fraunhofer.de

2452-3216 © 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ECF24 organizers 2452-3216 © 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ECF24 organizers

2452-3216 © 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ECF24 organizers 10.1016/j.prostr.2025.06.187