Integrated modeling framework for the interactions of plastic deformation, magnetic fields, and electrical circuits: Theory and applications to physics-informed real-time material monitoring

This study aims to develop a thermodynamic modeling framework for the electromagnetic-plastic deformation response coupled with circuit analysis. To accomplish this objective, we derived the thermodynamic balance laws for materials exposed to electromagnetic fields while undergoing plastic deformation. The balance laws serve as the foundation for refining the connection between the plastic deformation and electrical conductivity of materials. This study also modeled the relationship between dislocation density and Matthiessen's rule. The constitutive equations were subsequently implemented into a crystal plasticity model, thereby calibrating and validating the model. The derived modeling framework considers the 1^st and 2^nd laws of thermodynamics. The model was then transformed into a circuit model for a monitoring system by formulating equations to analyze the changes in material impedance resulting from the evolution of plastic deformation. This lays the groundwork for creating a monitoring system featuring a real-time prediction algorithm designed to assess material properties during manufacturing processes, thereby enhancing quality control and productivity. This monitoring system is used to monitor all materials in production lines of factories, where full-field measurement methods have limitations. Numerical simulations and experiments were conducted to validate the model and system performance. The results of these validation tests demonstrate that the model not only accurately predicts the relationship between electromagnetic fields and plastic deformation at the material level but also provides practical applicability within the realm of circuit theory, thus making it suitable for real-world system implementation.