Effect of strain rate sensitivity and cavity growth rate on failure of superplastic material

Abstract

Necking development and fracture strain of superplastic material under tensile load are analysed by introducing a model of cavity growth into the long wavelength approximation analysis which can describe the external neck development of specimens during deformation. The results show that both strain rate sensitivity m and cavity growth rate η have an important influence on the fracture strain of superplastic material. According to these results, a fracture diagram is presented in m–η coordinates, which is divided into three: a region in which material fails by macroscopic external necking, a region where cavity growth is predominant leading to fracture without pronounced external necking, and an intermediate region where both fracture modes occur. The prediction of fracture strain for various superplastic alloys exhibiting cavity growth during deformation is in good agreement with experimental results. The present analysis thus enables quantitative prediction of the effects of both strain rate sensitivity and cavity growth on superplastic fracture under uniaxial tension.

MST/491     

Some guidelines for promoting high temperature deformation of metallic alloys

Capacity to reach large deformation at high temperature is an important issue in many forming processes of metallic alloys. It is well known that a low value of the stress exponent (or a concomitant high value of the strain rate sensitivity parameter) is a key point for controlling resistance to necking. A first way for decreasing the stress exponent is to get superplastic properties but it frequently requires dealing with fine microstructures which can be difficult to produce and to preserve. Moreover, in the case of single phase alloys, like aluminum or magnesium alloys, superplastic deformation generally induces damage which can result in premature fracture or damaged components after forming. The aim of this paper is to give some guidelines for promoting high temperature deformation of metallic alloys, with a particular attention given to superplastic forming. The possibility to reduce the temperature of superplastic forming (SPF) for titanium alloys, the capacity to get a better understanding of the specificities of damage process in the case of superplastic deformation and the ability to get large strains to fracture avoiding the production of fine grains before strain are more specifically discussed.     

定向凝固NiAl合金的拉伸行为研究

研究了定向凝固NiAl-Mo(Hf)和NiAl-Fe(Nb)合金的拉伸行为和显微组织变化.结果表明,两种合金在一定的拉伸条件下均具有反常的屈服行为和中温脆性.反常屈服和中温脆性行为与合金中含有的Ni3Al相有关.两种合金在高温时还表现出高应变速率的超塑性变形行为.超塑性变形的主要机理是位错滑移和攀移产生的应变硬化与动态回复和动态再结晶的应变软化作用相平衡.超塑性变形试样的断口呈韧性特征,在断裂区有孔洞产生.     

Cavitation and cavity-induced fracture during superplastic deformation

The characteristics of fracture by cavitation in superplastic materials are reviewed. Particular attention is paid to the theoretical developmental aspects of cavity nucleation, cavity growth and cavity interlinkage. Various factors, including grain boundary sliding, impurity atoms or particles, phase proportion, deformation temperature, strain rate, strain and grain size, are discussed. Finally, methods for controlling cavitation during superplastic deformation are summarized, and problems which require further work are also presented.     

Influences of grain size on fracture of superplasticity

The cavity growth process during superplastic deformation has been studied. A model for this process is proposed based on the theory of grain-boundary-sliding (GBS) and the theory of cavity growth. According to the deduced equation, the relationship between fracture strain and grain size at a specific temperature and strain rate is analyzed and discussed. It shows that the total elongation is an approximated to linear function of the inverse grain size for the superplastic materials.     

Mechanisms of cavity growth in a fine-grained 7475 Al superplastic alloy

Under creep conditions, cavity growth may be controlled by vacancy diffusion or power-law creep. The two growth mechanisms are examined with reference to a superplastic 7475 Al alloy as a function of test temperature, superimposed strain rate and starting grain size. It is found that power-law cavity growth by plastic deformation of the matrix surrounding the cavities dominates at all test conditions. In addition, growth and interlinkage of cavities is an important parameter in controlling the ease and type of fracture and is enhanced by the ease of superplastic deformation.     

异步轧制AZ31镁合金板材的超塑性工艺及变形机制

经过异步轧制工艺获得AZ31镁合金薄板。在300~450℃范围内,分别通过5×10-3,1×10-3s-1和5×10-4s-1不同应变速率进行高温拉伸实验研究其超塑性变形行为,计算应变速率敏感指数m值、超塑性变形激活能Q及门槛应力σ0值。通过EBSD分析和扫描电镜观察拉伸断裂后的断口形貌,分析AZ31镁合金的超塑性变形机制。结果表明:AZ31镁合金的塑性变形能力随着变形温度的升高及应变速率的降低而增强。当拉伸温度为400℃、m=0.72、应变速率为5×10-4s-1时,AZ31具有良好的超塑性,伸长率最大为206%。温度为400℃时,异步轧制AZ31镁合金的超塑性变形是以晶格扩散控制的晶界滑移和基面滑移共同完成的。     

Microstructure and Elevated Temperature Tensile Behavior of Directionally Solidified Ni-rich NiAl-Mo(Hf) Alloy

The microstructure, high strain rate superplasticity and tensile creep behavior of directionally solidified (DS) NiAl-Mo(Hf) alloy have been investigated. The alloy exhibits dendritic structure, where dendritic arm is NiAl phase, interdendritic region is Ni3Al phase, and Mo-rich phase distributes in the NiAl and Ni3Al phases. The alloy exhibits high strain rate superplastic deformation behavior, and the maximum elongation is 104.2% at 1373 K and strain rate of 1.04×10-2 s-1. The balance between strain hardening (by dislocation glide) and strain softening (by dynamic recovery and recrystallization) is responsible for the superplastic deformation. All the creep curves of the DS NiAl-Mo(Hf) alloy have similar shape of a short primary creep and dominant steady creep stages, and the creep strain is great. The possible creep deformation mechanism was also discussed. The creep fracture data follow the Monkman-Grant relationship.     

Tensile flow and fracture behaviour of a superplastic Al-Ca-Zn alloy

The tensile flow behaviour in the range 275 to 550 ° C of an ultra-fine-grained superplastic Al-Ca-Zn alloy is reported. Under certain conditions of temperature and strain rate, superplastic ductility could be established. Fracture surfaces of tensile specimens tested in the above temperature range were examined by scanning electron microscopy and a correlation could be obtained between the ductility, as revealed by the tension tests, and the fracture behaviour. The fractographic studies also suggested a transition in the deformation process from grain deformation (mainly slip) at the lower temperatures to grain-boundary deformation (predominantly grain-boundary sliding) in the vicinity of 425 ° C.     

Superplasticity in NiAl intermetallics macroalloyed with iron

In this paper, we aim to examine the superplastic behavior of an extruded Ni–28.5Al–20.4Fe (at.%) alloy, which consists of β+γ phases with an average linear intercept grain size of 30–50 μm. Its tensile properties were determined at temperatures from 1123 to 1323 K and initial strain rates from 1.04×10⁻² to 1.04×10⁻⁴ s⁻¹. A maximum elongation of 233% was obtained at 1123 K and a strain rate of 5.2×10⁻⁴ s⁻¹. Transmission electron microscope (TEM) observation found many dislocation-free grains adjacent to grains with a high-dislocation density and subgrains and subgrain boundaries, which indicate that dynamic recrystallization has occurred as an efficient accommodation mechanism. Scanning electron microscope (SEM) examination of the fracture sample after superplastic deformation reveals many voids on the fracture surface. By correlating with the results of TEM observation, it is suggested that the superplastic deformation in this alloy should be controlled by a grain boundary sliding-based mechanism accommodated by the movement of dislocation and dynamic recrystallization.     

Failure analysis on gas pressure formed spherical domes of Pb–Sn eutectic alloy

Abstract

This paper addresses the issue of instability of deformation during gas pressure forming of superplastic sheets. With regard to fracture strain, the plastic behaviour of the spherical dome has been described in terms of the local effective stress and the effective strain. These quantities are equated to the uniaxial stress state. The limiting effective thickness strain is obtained utilising the relations between the strain rate sensitivity index and the fracture strain. The results are found to be in good agreement with the measured failure strains.     

SiCp/Al复合材料超塑性变形的断口特征

对SiCp/2024Al复合材料在不同温度下超塑性变形后的断口形貌进行了分析，结果表明，变形温度愈高，晶界结合强度愈低，沿晶断裂愈明显，晶界滑动愈易实现；超塑性变形需要强度适中的晶界结合；典型超塑变形条件下的断口呈晶界圆滑型沿晶断裂。     

Crack formation and oxidation in superplastically deformed Si3N4

Crack formation and oxidation during superplastic deformation of Si₃N₄ were studied and the superplastic forming ability of Si₃N₄ was discussed. Tensile deformation tests were conducted under a 1 atm nitrogen atmosphere at 1600 °C, and under a constant crosshead speed with an initial strain rate of 2×10^–5s^–1. The microstructures of superplastically deformed specimens were observed by SEM. The relation between chemical composition and microstructure was determined by EPMA. After 280% deformation (at fracture), the formation of regions rich in glassy phase was observed. These regions, supposed to be formed due to oxidation of cracks, appeared just before fracture. The present material is capable of being deformed up to strains of 210%.     

Investigation of Subboundaries Evolution in Superplastically Deformed NiAl by Positron Lifetime

In order to study the subboundaries evolution in superplastically deformed NiAl,the positron lifetime change during superplastic deformation process was measured.It is shown that the superplastic deformation of NiAl has not influence on its τ2,the newly recrystallized grain boundaries formed during entire superplastic deformation process belong to the calegory of subboundaries and have not contribution to the superplastic strain.     

7B04铝合金超塑性变形行为

针对7B04铝合金开展了变形温度为470~530℃,应变速率为0.0003~0.01s~(-1)的高温超塑性拉伸实验,研究了材料的超塑性变形行为和变形机制。结果表明,7B04铝合金的流动应力随着变形温度的升高和应变速率的降低而逐渐减小,伸长率随之增加;在变形温度为530℃,应变速率为0.0003s~(-1)时,7B04铝合金的伸长率达到最大1105%,超塑性能最佳;应变速率敏感性指数m值均大于0.3,且随变形温度的升高而增加;在500~530℃的变形温度范围内,m值大于0.5,表明7B04铝合金超塑性变形以晶界滑动为主要变形机制;变形激活能Q为190kJ/mol,表明7B04铝合金的超塑性变形主要受晶内扩散控制;7B04铝合金超塑性变形中在晶界附近有液相产生,且适量的液相有利于提高材料的超塑性能。     

Neck formation and cavitation in the superplastic Zn-22% Al eutectoid

The mechanical behaviour of the superplastic Zn-22% Al eutectoid is divisible into three distinct regions. Experiments show the deformation is quasi-uniform at intermediate strain rates in region II, but neck formation is important at low strain rates in region I. Extensive cavitation occurs in regions I and II, but fracture in region I is due to necking. The results provide strong evidence for a decrease in the true value of the strain rate sensitivity in region I.     

Low-temperature superplasticity of β-stabilized Ti-43Al-9V-Y alloy sheet with bimodal γ-grain-size distribution

The superplasticity of Ti-43Al-9V-0.2Y alloy sheet hot-rolled at 1100 ℃ was systematically investigated in the temperature range of 750-900 ℃ under an initial strain rate of 10-4 s-1.A bimodal γ grain-distribution microstructure of TiA1 alloy sheet,with abundant nano-scale or sub-micron γ laths embed-ded inside β matrix,exhibits an impressive superplastic behaviour.This inhomogeneous microstructure shows low-temperature superplasticity with a strain-rate sensitivity exponent of m =0.27 at 800 ℃,which is the lowest temperature of superplastic deformation for TiAl alloys attained so far.The maximum elongation reaches ～360％ at 900 ℃ with an initial strain rate of 2.0 × 10-4 s-1.To elucidate the softening mechanism of the disordered β phase during superplastic deformation,the changes of phase composi-tion were investigated up to 1000 ℃ using in situ high-temperature X-ray diffraction (XRD) in this study.The results indicate that β phase does not undergo the transformation from an ordered L20 structure to a disordered A2 structure and cannot coordinate superplastic deformation as a lubricant.Based on the microstructural evolution and occurrence of both y and β dynamic recrystallization (DR) after tensile tests as characterized with electron backscatter diffraction (EBSD),the superplastic deformation mecha-nism can be explained by the combination of DR and grain boundary slipping (GBS).In the early stage of superplastic deformation,DR is an important coordination mechanism as associated with the reduced cavitation and dislocation density with increasing tensile temperature.Sufficient DR can relieve stress concentration arising from dislocation piling-up at grain boundaries through the fragmentation from the original coarse structures into the fine equiaxed ones due to recrystallization,which further effectively suppresses apparent grain growth during superplastic deformation.At the late stage of superplastic de-formation,these equiaxed grains make GBS prevalent,which can effectively avoid intergranular cracking and is conducive to the further improvement in elongation.This study advances the understanding of the superplastic deformation mechanism of intermetallic TiAl alloy.     

采用吊垂式拉伸试验机探讨超塑性变形速度的提高方式

在吊锤式拉伸试验机上研究了2024铝合金在自由延伸过程中每个时期的应变速度与显微组织的变化,发现经过恒速应变后,金属的超塑性变形会出现应变速度不断加快,实际应变速度比恒速应变速度可提高1.25个数量级.并提出:材料在低温、高应变速度下难以获得理想的超塑性效果;在提高超塑性成形速度的同时,适当升高变形温度,可使工件超塑性恒温锻造的应变速度提高8～10倍.     

TC4钛合金激光焊接/超塑成形组合工艺研究

本文将超塑成形(SPF)和激光焊接技术(LW)相结合,开发激光焊接/超塑成形组合工艺(LW/SPF),研究TC4钛合金激光叠焊接头的超塑性变形行为,并对超塑性变形前后的显微组织进行分析.结果表明,TC4钛合金激光叠焊接头能够承受焊板的变形,试样在母材断裂,并通过四层板的模拟件研制验证了超塑成形/激光焊组合工艺工业应用的可行性.     

The stress-strain rate behaviour of superplastic Zn-Al eutectoid alloy

The stress-strain rate behaviour of a superplastic Zn-22% Al alloys was investigated by the differential strain rate and constant load cycling tests on an Instron machine. A region with a rate sensitivity approaching unity was observed at low strain rates. On increasing the strain rate, a transition to the superplastic region occurred through an intermediate region of lower m (0.35). These observations are interpreted in terms of a transition from diffusional creep to superplastic flow with a threshold stress for superplastic deformation.