Elevated temperature deformation behavior of an Al-8.4 wt pct Fe-3.6 wt pct Ce alloy

The elevated temperature deformation characteristics of a rapidly solidified Al-8.4 wt pct Fe-3.6 wt pct Ce alloy have been investigated. Constant true strain rate compression tests were performed between 523 and 823 K at strain rates ranging from 10⁻⁶ to 10⁻³ s⁻¹. At temperatures below approximately 723 K, the alloy is significantly stronger than oxide dispersion strengthened (ODS) aluminum. However, at higher temperatures, the strength of the Al-Fe-Ce alloy falls rapidly with increasing temperature while ODS aluminum exhibits an apparent threshold stress. It is shown that particle coarsening cannot fully account for the reduction in strength of the Al-Fe-Ce alloy at elevated temperatures. The true activation energy for deformation of the Al-Fe-Ce alloy at temperatures between 723 and 773 K is significantly greater than that for self-diffusion in the matrix. This is unlike the behavior of ODS alloys, which contain nondeformable particles and exhibit true activation energies close to that for self-diffusion in the matrix. Since abnormally high true activation energies for deformation are also exhibited by materials containing deformable particles, such as γ^′ strengthened superalloys, it is concluded that elevated temperature deformation in ythe Al-Fe-Ce alloy involves deformation of both the matrix and the precipitates. The loss of strength of the Al-Fe-Ce alloy appears to be related to a reduction in strength of at least some of the second phase particles at temperatures above 723 K. Formerly Research Assistant, Department of Materials Science and Engineering, Stanford University.     

Tracer diffusion of63Ni in Fe-17 wt pct Cr-12 wt pct Ni

The tracer diffusion of⁶³Ni in Fe-17 Cr-12 Ni by both volume and grain boundary transport has been studied from 600° to 1250°C. The use of an RF sputtering technique for serial sectioning allowed the determination of very small volume diffusion coefficients at the lower temperatures. Volume diffusion of nickel in this alloy was observed to be much slower than in pure iron or austenitic stainless steel at comparable temperatures. The volume diffusion coefficient is described byD _v =8.8 exp (−60,000/RT) cm²/s and grain boundary diffusion is described by σD _gb =3.7×10⁻⁹ exp (−32,000/RT) cm³/s. R. A. PERKINS, formerly Presidential Intern, Metals and Ceramics Division, Oak Ridge National Laboratory, Oak, Ridge, Tenn. 37830, is     

Displacive transformations in Au-18 wt pct Cu-6 wt pct Al

A gold alloy with 18 wt pct Cu and 6 wt pct Al undergoes a reversible displacive phase transformation between an incompletely ordered L2₁ parent phase and a tetragonal product. The characteristics of these transformations were studied using acoustic emission, dilatometry, X-ray diffraction, and metallography. The morphology of the transformation products, the structure of the parent phase, and the generation of significant acoustic emission during the transformations indicate that they are at least quasi-martensitic, if not martensitic, and that this system is an example of a β-phase shape-memory alloy (SMA). The onset temperatures of the transformations depend on the prior thermal history of the sample. The martensite start (M _s ) temperature is between 30 °C and 20 °C. The system exhibits hysteresis and will revert to the parent phase when reheated, with an austenite start (A _s ) temperature between 55 °C and 80 °C. However, freshly cast or solution-annealed and quenched samples of the alloy do not transform to the tetragonal phase. Aging of such material at temperatures between 30 °C and 200 °C is required before they will manifest the displacive transformation. The “martensite” phase is considerably more resistant to aging-induced stabilization than that of most other SMAs.     

High-strain-rate superplastic behavior of equal-channel angular-pressed 5083 Al-0.2 wt pct Sc

Tensile tests were carried out at temperatures of 673 to 773 K and strain rates of 1×10⁻³ to 1 s⁻¹ on an ultrafine-grained (UFG) 5083 Al alloy containing 0.2 wt pct Sc fabricated by equal-channel angular pressing, in order to examine its high-strain-rate superplastic characteristics. The mechanical data for the alloy at 723 and 773 K exhibited a sigmoidal behavior in a double logarithmic plot of the maximum true stress vs true strain rate. The strain-rate sensitivity was 0.25 to 0.3 in the low-( <5×10⁻³ s⁻¹) and high- ( >5×10⁻² s⁻¹) strain-rate regions, and ∼0.5 in the intermediate-strain-rate region (5×10⁻³ s⁻¹< <5 × 10⁻² s⁻¹). The maximum elongation to failure of ∼740 pct was obtained at 1×10⁻² s⁻¹ and 773 K. By contrast, no sigmoidal behavior was observed at 673 K. Instead, the strain-rate sensitivity of 0.3 was measured in both intermediate-and low-strain-rate regions, but it was about 0.25 in the high-strain-rate region. High-strain-rate superplasticity (HSRS) in the intermediate-strain-rate region at 723 and 773 K was dominated by grain-boundary sliding (GBS) associated with continuous recrystallization and preservation of fine recrystallized grains by second-phase particles. However, the activation energy for HSRS of the present alloy was lower than that predicted for any standard high-temperature deformation mechanism. The low activation energy was likely the result of the not-fully equilibrated microstructure due to the prior severe plastic deformation (SPD). For 673 K, the mechanical data and the microstructural examination revealed that viscous glide was a dominant deformation mechanism in the intermediate- and low-strain-rate regions. Deformation in the high-strain-rate region at all testing temperatures was attributed to dislocation breakaway from solute atmospheres.     

The low strain tensile behavior of U-7.5 wt pct Nb-2.5 wt pct Zr

The stress-strain response of polycrystalline, γ-quenched U-7.5 wt pct Nb-2.5 wt pct Zr alloy was studied as a function of strain rate and compared to equilibrium stress-strain tests performed by allowing the strain to reach a maximum value at incrementally increasing stresses. Equilibrium stress-strain tests were also performed on prestressed samples. Sheet tensile specimens were held at various states of strain in an X-ray diffractometer to determine crystal structural changes during deformation. Prestressed tensile bars were sectioned and examined metallographically and with the X-ray diffractometer. Two linear regions were observed in the equilibrium stress-strain tests: a low stress region with a slope of 5.3 to 5.5 x 10⁶ psi, and a region above 40,000 psi with a slope of 3.3 x 10⁶ psi. Finite strain rates tended to increase both slopes. The diffractometer experiments yielded plots of lattice parameter vs strain which showed a shift from a bcc structure of the γ^s phase, to a bct structure of the γ₀ phase between 1 and 3 pct deformation. It is postulated that this is a thermoelastic martensite transformation. A semiempirical equation was developed which describes the equilibrium stress-strain behavior of this alloy in terms of a stress induced phase transformation.     

Mushy zone morphology during directional solidification of Pb-5.8 wt pct Sb alloy

The Pb-5.8 wt pct Sb alloy was directionally solidified with a positive thermal gradient of 140 K cm⁻¹ at a growth speed ranging from 0.8 to 30 μm s⁻¹, and then it was quenched to retain the mushy zone morphology. The morphology of the mushy zone along its entire length has been characterized by using a serial sectioning and three-dimensional image reconstruction technique. Variation in the cellular/dendritic shape factor, hydraulic radius of the interdendritic region, and fraction solid along the mushy zone length has been studied. A comparison with predictions from theoretical models indicates that convection remarkably reduces the primary dendrite spacing while its influence on the dendrite tip radius is not as significant.     

The thermal activation energy for fatigue of Fe- 1 pct Cr- 0.5 pct Mo

The temperature dependence of fatigue crack propagation is considered in an Fe-1 pct Cr-0.5 pct Mo alloy steel. This material was tested at temperatures between 425 and 550 °C, a frequency of 1 Hz, and anR-ratio of 0.1. It is shown that the effect of temperature can be explained in terms of a thermal activation energy for fatigue. The magnitude of this activation energy is a function of ΔK and varies from more than 150 kJ/mole at 15 MPa√m to 30 kJ/mole above 30 MPa√m. The magnitude of these activation energies supports the idea that oxidation, and not creep, is the rate-controlling time-dependent process for the test conditions studied.     

Stress-assisted transformation in Ti-60 wt pct Ta alloys

An investigation of the influence of processing variables on mechanical properties and phase development for a Ti-60 wt pct Ta (Ti-28.5 at. pct Ta) alloy was conducted. The alloy was hot-rolled, subjected to heat-treatment temperatures above the β (bcc) transus (1 hour at 700 °C, 800 °C, or 900 °C), and water quenched. All heat treatment produced a combination of metastable β (bcc) and metastable α″ (orthorhombic martensite), with the amount of retained β essentially independent of heat treatment, ranging from 20 to 33 vol pct. Deformation of as-rolled and heat-treated tension specimens showed an anomalous leveling of the stress-strain curve in the stress-strain curves at low strains. X-ray diffraction (both simple 2ϑ diffractometry and texture analysis) on both deformed and undeformed material determined that the leveling of the stress-strain curve was a result of the β→α″ martensitic transformation. The stress required to initiate the transformation increased with prequench temperature. This was determined to be due to the presence of athermal ω. Grain growth kinetics have been determined in the course of this work.     

Microstructure and corrosion behavior of as-cast and heat-treated Al-4.5 Wt pct Cu-2.0 wt pct Mn alloys

The microstructure and corrosion behavior of as-cast and heat-treated Al-4.5 pct Cu-2.0 pct Mn alloy specimens solidified at various cooling rates were investigated. The equilibrium phases Al₆Mn and θ-Al₂Cu, which are observed in the conventionally solidified alloy in the as-cast condition, were not detected in rapidly solidified (melt-spun) material. Instead, the ternary compound Al₂₀Cu₂Mn₃ was present in addition to the α phase, which was present in all cases. The morphological and kinetic nature of corrosion was investigated metallographically and through potentiostatic techniques in 3.5 wt pct NaCl aqueous solution. Corrosion of the as-cast material was described by two anodic reactions: corrosion of the intermetallic phases and pitting of the α-Al solid solution. The corrosion rate increased with cooling rate from that for the furnace-cooled alloy to that for the copper mold-cast alloy and, subsequently, decreased in the rapidly solidified alloy. In the heat-treated material, corrosion could be described by two anodic reactions: corrosion of Al₂₀Cu₂Mn₃ precipitate particles and pitting of the α-Al matrix. S.M. Skolianos, formerly Graduate Student, Department of Metallurgy, University of Connecticut     

The quench sensitivity of cast Al-7 wt pct Si-0.4 wt pct Mg alloy

The effect of quenching condition on the mechanical properties of an A356 (Al-7 wt pct Si-0.4 wt pct Mg) casting alloy has been studied using a combination of mechanical testing, differential scanning calorimetry (DSC), and transmission electron microscopy (TEM). As the quench rate decreases from 250 °C/s to 0.5 °C/s, the ultimate tensile strength (UTS) and yield strength decrease by approximately 27 and 33 pct, respectively. The ductility also decreases with decreasing quench rate. It appears that with the peak-aged condition, both the UTS and yield strength are a logarithmic function of the quench rate,i.e., UTS orσ _y =A logR +B. The termA is a measure of quench sensitivity. For both UTS and yield strength of the peak-aged A356 alloy,A is approximately 32 to 33 MPa/log (°C/s). The peak-aged A356 alloy is more quench sensitive than the aluminum alloy 6063. For 6063,A is approximately 10 MPa/log (°C/s). The higher quench sensitivity of A356 is probably due to the high level of excess Si. A lower quench rate results in a lower level of solute supersaturation in the α-Al matrix and a decreased amount of excess Si in the matrix after quenching. Both of these mechanisms play important roles in causing the decrease in the strength of the peak-aged A356 with decreasing the quench rate.     

Creep behavior of an Al-2. 0 wt pct Li alloy in the temperature range 300 °C to 500 °C

The elevated temperature deformation behavior of an Al-2. 0 wt pct Li alloy in the temperature range 300 °C to 500 °C was studied using constant extension-rate tension testing and constant true-stress creep testing under both isothermal and temperature cycling conditions. Optical microscopy and transmission electron microscopy (TEM) were employed to assess the effect of deformation on microstructure. The data showed that the stress exponent,n, has a value of about 5. 0 at temperatures above theα +δAlLi solvus (approximately 380 °C) and that subgrains form during plastic deformation. Models for dislocation-climb and dislocation-glide control of creep were analyzed for alloys deformed in the temperature range of stability of the terminal AlLi solid solution. A climb model was shown to describe closely the behavior of this material. Anomalous temperature dependence of the activation energy was observed in this same temperature range. This anomalous behavior was ascribed to unusual temperature dependence of either the Young’s modulus or the stacking fault energy, which may be associated, in turn, with a disorder-order transformation on cooling of the alloy. Formerly with the Materials Engineering Section. Department of Mechanical Engineering, Naval Postgraduate School.     

The evolution of grain boundary character during superplastic deformation of an Al-6 pct Cu-0.4 pct Zr alloy

The evolution of microstructure, texture, and microtexture in an Al-6 pct Cu-0.4 pct Zr alloy was studied during mechanical testing at 480 °C and a strain rate of 5·10⁻⁴ s⁻¹. The as-processed material had an elongated, banded microstructure and a deformation texture with orientation distribution along the β-orientation fiber. The true strain vs true stress curve exhibited three stages: I, II, and III. Work hardening occurred in stages I and III, whereas nearly steady-state behavior was observed in stage II. A bimodal distribution of boundary disorientation angles was evident in as-processed material and persisted into stage I, with peaks at 5–15 deg in the low-angle boundary (LAB) regime and at 45–60 deg in the high-angle boundary (HAB) regime. An increase in strain rate sensitivity coefficient, m, in stage I was accompanied by fragmentation of the initial microstructure, leading to the formation of new grains. During stage II the strain rate sensitivity coefficient, m, attained a value of 0.5, which is consistent with the onset of grain boundary sliding. In stage III, the texture and the grain boundary disorientation distribution became randomized while the m value decreased. Grain elongation and cavity formation at second-phase particles and along grain boundaries were seen in samples deformed to failure. The as-processed microstructure is described in terms of deformation banding, and a model for the evolution of such a structure during superplastic deformation is proposed.     

The effect of grain size on low-cycle fatigue behavior of Al-2024 polycrystalline alloy

Two different sets of fatigue specimens were heat treated at different times or temperatures to investigate the effect of grain size on the low-cycle fatigue behavior of Al-2024 polycrystalline alloy. Strain-controlled low-cycle fatigue testing with a strain rate of 1×10⁻⁴ s⁻¹ was conducted at room temperature. The fatigue response of the alloy was evaluated macroscopically in terms of cyclic stress strain response and microscopically in terms of appearance of cyclic slip bands. The cyclic stress strain response of Al-2024 polycrystalline alloy exhibited a definite plateau region where saturation stress remained constant with plastic strain. It was found that the smaller the grain size, the lower the saturation stress and the longer the plateau, whereas the larger the grain size, the higher the saturation stress and shorter the plateau (i.e., reverse grain size effect). Microscopic observations using scanning electron microscope revealed that persistent slip bands (PSBs) were observed at 45 deg orientations from the grain boundary. The volume fraction of PSBs was higher in small-grained Al-2024 polycrystalline alloy as compared to large-grained Al-2024 polycrystalline alloy. This article is based on a presentation given in the symposium “Dynamic Deformation: Constitutive Modeling, Grain Size, and Other Effects: In Honor of Prof. Ronald W. Armstrong.” March 2–6, 2003, at the 2003 TMS/ASM Annual Meeting, San Diego, California, under the auspices of the TMS/ASM Joint Mechanical Behavior of Materials Committee.     

A structural investigation of multiple aging of Al-7 wt pct Zn-2.3 wt pct Mg

A transmission electron microscopy study of the structural changes which attend aging at 180°C with and without pre-aging at 100°C was conducted on a high purity aluminum alloy containing 6.8 pct Zn and 2.3 pct Mg. The refinement in precipitate dispersion accompanying multiple aging is caused by the operation of aging sequences which differ from those occurring in material given the single age at 180°C only. The high nucleation rate which occurs during the low temperature pre-aging treatment is responsible for the observed precipitate refinement. The results of this investigation appear to agree favorably with the Pashleyet al. model of multiple aging.     

The influence of the nanosized reinforcing phase on the behavioral features of the 1953T1 aluminum alloy under cyclic load

The results of an investigation into the interrelation between the fatigue behavior (number N of cycles to failure) and the level of surface residual stresses (σ) of the cyclic deformation of the samples of high-tensile aluminum alloy with the nanosized reinforcing phase, which is used for the production of drill pipes, are presented. The tests were performed at the zero-to-tension stress cycle with a maximum tensile load of 160 MPa. To determine the level of σ, a DRP-RIKOR X-ray diffractometer was used. As a result, a substantial increase in fatigue strength (an increase in the number of cycles to failure) is found in the presence of the starting compressional surface residual stresses of about −120...−200 MPa (0.25–0.4 of the yield strength of the alloy). The dependence σ(N) has a nonmonotonic character that can be attributed to the nonuniformity of the local plastic deformation near the dispersed intermetallic inclusions. However, the indicated dependence with the locally cyclic character tends to an increase, which is expressed by a linear function, allowing us to evaluate and forecast the failure according to the level of the surface residual stresses.     

Microtexture evolution during annealing and superplastic deformation of Al-5 pct Ca-5 pct Zn

The microtexture and grain boundary misorientation distributions (i.e., mesotexture) of the superplastic alloy Al-5 pct Ca-5 pct Zn have been investigated in the as-processed condition, after annealing at 520 °C (for times ranging from 7 minutes to 90 hours) and after tensile straining in the transverse direction (TD). Three different superplastic straining conditions were considered: 550 °C/10⁻² s⁻¹, 550 °C/10⁻¹ s⁻¹, and 400 °C/10⁻² s⁻¹. Microtexture data were obtained by means of computer-aided electron backscatter diffraction analysis methods. The retention of the deformation texture of the as-received material and the development of an increasingly bimodal grain boundary misorientation distribution following static annealing are consistent with the occurrence of recovery and continuous recrystallization. During superplastic straining, deformation texture components are also retained, but with a change in the grain boundary misorientation distribution toward random, indicating that grain switching occurs during grain boundary sliding (GBS). At the midlayer, however, a change from an initial texture component near the Cu-type texture component toward the Brass texture component, {011}〈211〉, was observed even as the misorientation distribution became more random. This change in texture component is associated with the occurrence of single slip during superplastic flow.     

Deformation behavior of dilute SnBi(0.5 to 6 at. pct) solid solutions

Tensile and creep tests were conducted to characterize the deformation behavior of four dilute SnBi alloys: SnBi0.5 at. pct, SnBi1.5 at. pct, SnBi3 at. pct, and SnBi6 at. pct, the last two being supersaturated solid solutions at room temperature. The test temperatures were − 20 °C, 23 °C, 90 °C, and 150 °C, and the strain rates ranged from approximately 10⁻⁸ to 10⁻¹ 1/s. In the tensile tests, all the alloys showed strain-hardening behavior up to room temperature. At higher temperatures, only the higher-Bi-content alloys exhibited strain softening. The deformation behavior of the alloys can be divided into two stress regimes, and the change from the low-stress regime to the high-stress regime occurred at around 6 × 10⁻⁴<σ/E<7.5 × 10⁻⁴. The results suggest that, at the low-stress regime, the rate-controlling deformation mechanism changes from dislocation climb to viscous glide with the increasing Bi content of the alloy. At the high-stress regime, the activation energy of deformation is about equal in all the alloys (∼60 kJ/mol) and the stress exponents are high (10<n<12.5). Unlike in the other alloys, bismuth precipitated at room temperature from the solution-annealed and quenched SnBi6 at. pct alloy by the discontinuous mechanism. This strongly affects the mechanical properties and makes the alloy brittle at lower test temperatures. A comparison of the deformation behavior of the dilute SnBi alloys to that of the eutectic SnBi alloy suggests that the deformation of eutectic structure is controlled by the Sn-rich phase containing the equilibrium amount of dissolved Bi.     

Low-Cycle fatigue of dispersion-strengthened copper

The cyclic deformation behavior of a dispersion-strengthened copper alloy, GlidCop Al-15, has been studied at plastic strain amplitudes in the range 0.1 pct ≤Δε _p/2 ≤ 0.8 pct. Compared to pure polycrystalline copper, the dispersion-strengthened material exhibits a relatively stable cyclic response as a consequence of the dislocation substructures inherited from prior processing and stabilized by the A1₂O₃ particles. These dislocation structures remain largely unaltered during the course of deformation; hence, they do not reveal any of the features classically associated with copper tested in fatigue. At low amplitudes, the fatigue lifetimes of the dispersion-strengthened copper and the base alloy are similar; however, the former is more susceptible to cracking at stress concentrations because of its substantially greater strength. This similarity in fatigue lifetimes is a consequence of the dispersal of both deformation and damage accumulation by the fine grain size and dislocation/particle interactions in the GlidCop alloy. The operation of these mechanisms is reflected in the fine surface slip markings and rough fracture surface features for this material. Formerly Graduate Research Assistant, University of California, Davis, CA     

Observations on the faceted fatigue fracture of cast Co−Cr−Mo alloy used for surgical implants

Fatigue crack propagation behavior of cast Co−Cr−Mo alloy used for surgical implants is studied at room temperature with the stress intensity factor range, ΔK, between 20 and , corresponding to a crack growth rate,da/dN, between 10⁻⁵ and 10⁻² mm/cycle. Faceted fatigue fractures are observed to be the dominant fracture features of the alloy under all tested conditions. The characteristics of the faceted fatigue fractures are discussed and identified. The development of facets seems to be a consequence of the low stacking fault energy of the alloy since this results in a dense structure of stacking fault intersections. Grain size has little effect on the occurrence of faceted fatigue fractures in cast Co−Cr−Mo alloy. Modifying the composition of the base alloy with Ni-additions increases the fracture ductility of the alloy.     

The effects of silicon on the reaction between solid iron and liquid 55 wt pct Al−Zn baths

The effect of various silicon levels on the reaction between iron panels and Al-Zn-Si liquid baths during hot dipping at 610°C was studied. Five different baths were used: 55Al−0.7Si−Zn, 55Al−1.7Si−Zn, 55Al−3.0Si−Zn, 55Al−5.0Si−Zn, and 55Al−6.88Si−Zn (in wt pct). The phases which formed as a result of this reaction were identified as Fe₂Al5 and FeAl3 (binary Fe−Al phases with less than 2 wt pct Si and Zn in solution),T1, T2, T4, T8, andT _5H (ternary Fe−Al−Si phases), andT _5C (a quaternary Fe−Al−Si−Zn phase). Compositional variations through the reaction zone were determined. The phase sequence in the reaction zone of the panel dipped for 3600 seconds in the 1.7 wt pct Si bath was iron panel/(Fe₂Al₅+T ₁)/FeAl₃/(T _5H+T _5C)/overlay. In the panel dipped for 1800 seconds in the 3.0 wt pct Si bath the reaction zone consisted of iron panel/Fe₂Al₅/(Fe₂Al₅+T ₁)/T ₁/FeAl₃/(FeAl₃+T ₂)/T _5H/overlay. In the panel dipped for 3600 seconds in the 6.88 wt pct Si bath the phase sequence was iron panel/Fe₂Al₅/(Fe₂Al₅+T1)/(T1+FeAl3)/(T1+T2)/T2/T8/T4/overlay. The growth kinetics of the reaction zone were also studied. A minimum growth rate for the reaction zone which formed from a reaction between the iron panel and molten Al−Zn−Si bath was found in the 3.0 wt pct Si bath. The growth kinetics of the reaction layers were found to be diffusion controlled in the 0.7, 1.7, and 6.88 wt pct Si baths, and interface controlled in the 3.0 and 5.0 wt pct Si baths. The presence of the interface between theT2/T5H, Fe2Al5/T ₁, orT ₁/FeAl₃ phases is believed responsible for the interface controlled growth kinetics exhibited in the 3.0 and 5.0 wt pct Si baths.