Yield point behavior in extruded aluminum rod

The microstructure of aluminum, extruded under industrial conditions at 250°C has been investigated in relation to the purity of the billet. Electron microscopy was used to observe the substructure and Kikuchi diffraction techniques were used to measure boundary angles and thus distinguish between recrystallization and repolygonization for samples of two different purities (99.7 pct Al and 99.99 pct Al) extruded under identical conditions. High tensile flow stresses of about 8000 to 9000 psi (55 to 62 MN/m²) were observed in specimens taken from the first sections of the high purity extrusion. These high strength levels were attributed to the presence of fine microstructure. When small recrystallized grains (0.5 to 2.0 μm diam) were present a yield drop was observed. This phenomenon is associated with the condition where nearly all the dislocations are likely to be immobile. The absence of a yield point in the 99.7 pct purity aluminum extruded under the same conditions as the 99.99 pct purity aluminum is due to the existence of fine subgrains instead of the fine recrystallized structure. A small yield point in 99.7 pct aluminum was induced by subsequent heat treatment resulting in the formation of small recrystallized grains of similar character to those in the higher purity extrusion. Formerly Research Assistant, Department of Mechanical Engineering, University of Waterloo, Waterloo, Ontario.     

Strain-path effects on the evolution of microstructure and texture during the severe-plastic deformation of aluminum

Microstructure and texture evolution during the severe-plastic deformation (SPD) of unalloyed aluminum were investigated to establish the effect of processing route and purity level on grain refinement and subgrain formation. Two lots of aluminum with different purity levels (99.998 pct Al and 99 pct Al) were subjected to large plastic strains at room temperaturevia four different deformation processes: equal-channel angular extrusion (ECAE), sheet rolling, conventional conical-die extrusion, and uniaxial compression. Following deformation, microstructures and textures were determined using orientation-imaging microscopy. In commercial-purity aluminum, the various deformation routes yielded an ultrafine microstructure with a ∼1.5-μm grain size, deduced to have been formedvia a dynamic-recovery mechanism. For high-purity aluminum, on the other hand, the minimum grain size produced after the various routes was ∼20 μm; the high fraction of high-angle grain boundaries (HAGBs) and the absence of subgrains/deformation bands in the final microstructure suggested the occurrence of discontinuous static recrystallization following the large plastic deformation at room temperature. The microstructure differences were underscored by the mechanical properties following four ECAE passes. The yield strength of commercial-purity aluminum quadrupled, whereas the high-purity aluminum showed only a minor increase relative to the annealed condition.     

Production of Wire From AA7277 Aluminum Chips via Friction-Stir Extrusion (FSE)

In this research, fully consolidated wires from aluminum alloy AA7277 machining chips were produced by the friction-stir extrusion (FSE) process. The components used in the friction-stir extrusion process consist of a stationary cartridge and a rotating plunger with a scroll-faced head. The rotating plunger was rotated at three different speeds. Optical microscopy was used to probe the microstructures formed in the wires. The hardness profile of each sample is characterized using a Vickers microhardness tester. In this work, surface quality is sufficient by using a rotation speed of 160 rpm. Cold crack and hot crack defects were shown on wires fabricated using either too low or too high plunger rotation speeds. The microstructure of extruded wire is composed of fully equiaxed, recrystallized fine grains in the center of samples. The microhardness tests show an uneven distribution, and the hardness of the center was lower than that of the parent metal. The tensile tests revealed that the mechanical properties of the extruded wires were comparable with parent material.     

Superplastic behavior of spray-deposited 5083 Al

A 5083 Al alloy was synthesized using spray deposition processing with N₂ as the atomization gas. It was noted that the grains that were present in as-spray-deposited 5083 Al were equiaxed with an average size of 15.2 μm. The matrix of the material was supersaturated with Mg and Mn. The asspray-deposited microstructure contained irregular pores with porosity in the range of 0.1 to 5.4 vol pct, depending on spatial location in the preform. The spray-deposited alloy was thermomechanically processed using extrusion and multiple-pass warm rolling to reduce grain size and close porosity. It was observed that spray-deposited 5083 Al exhibited superplasticity following thermomechanical processing by extrusion followed by rolling. Superplasticity was observed in the 500 °C to 550 °C temperature range and 3 × 10⁻⁵ to 3 × 10⁻³ s⁻¹ strain rate range. The corresponding strain-rate-sensitivity factors were in the 0.25 to 0.5 range and increased with decreasing strain rate. A maximum elongation of 465 pct was noted at 550 °C and 3 × 10⁻⁵ s⁻¹. The spray-deposited 5083 Al, thermomechanically processed by direct rolling, exhibited superplasticity in the same temperature and strain rate ranges as those for the extruded and rolled materials. The superplastic elongation of the spray-formed and rolled material was relatively low, being in the range of 250 to 300 pct. The deformation behavior is discussed in light of the presence of porosity in the microstructure.     

Dispersion strengthening in a hypereutectic Al-Si alloy prepared by extrusion of rapidly solidified powder

When a hypereutectic aluminum-silicon alloy containing 16 wt pct silicon was rapidly solidified into powder using the spinning water atomization process, the individual powder grains were predominantly aluminum that was supersaturated with silicon and also contained well-dispersed 0.02-μm silicon particles. Although the silicon particles grew when the powder was extruded into a bar at temperatures from 673 to 803 K at an extrusion ratio of 4.3 and an extrusion speed of 0.9 mm/s, the average diameter was maintained on a submicron level. When the extrusion temperature was decreased from 803 to 673 K, the average diameter of the silicon particles in the extruded bar decreased from 0.8 to 0.5 μm, while the Vickers hardness (HV) and the ultimate tensile strength of the extruded bar increased from 120 to 160 (HV) and from 330 to 500 MPa, respectively. Both the hardness and the tensile strength of the extruded bars were several times higher than those of conventionally cast bars of the same alloy with cooling rates from 10⁻¹ to 10² K/s. On the other hand, the elongation decreased from 5.5 to 3.1 pct when the extrusion temperature was decreased from 803 to 673 K.     

Fatigue crack initiation and microcrack propagation in X7091 type aluminum P/M alloys

Fatigu crack initiation in extruded X7091 RSP-P/M aluminum type alloys o°Curs at grain boundaries at both low and high stresses. By a process of elimination this grain boundary embrittlement was attributed to Al₂O₃ particles formed mainly during atomization and segregated to some grain boundaries. It is not due to the small grain size, to Co₂Al₉, to η precipitates at grain boundaries, nor to a precipitate free zone. Thermomechanical processing after extrusion of X7091 with 0.8 pct Co was done by Alcoa to produce large recrystallized grains. This resulted in initiation of fatigue cracks at slip bands, and the resistance to initiation of fatigue cracks at low stresses was much greater. Microcrack growth is, however, much faster in the thermomechanically treated samples, as well as in ingot alloys, than in extruded and aged X7091.     

Fatigue Crack Initiation and Microcrack Propagation in X7091 Type Aluminum P/M Alloys

Fatigue crack initiation in extruded X7091 RSP-P/M aluminum type alloys occurs at grain boundaries at both low and high stresses. By a process of elimination this grain boundary embrittlement was attributed to A1₂O₃ particles formed mainly during atomization and segregated to some grain boundaries. It is not due to the small grain size, to Co₂Al₉, to 17 precipitates at grain boundaries, nor to a precipitate free zone. Thermomechanical processing after extrusion of X7091 with 0.8 pct Co was done by Alcoa to produce large recrystallized grains. This resulted in initiation of fatigue cracks at slip bands, and the resistance to initiation of fatigue cracks at low stresses was much greater. Microcrack growth is, however, much faster in the thermomechanically treated samples, as well as in ingot alloys, than in extruded and aged X7091.     

Effect of Nd Additions on Extrusion Texture Development and on Slip Activity in a Mg-Mn Alloy

Two Mg-1 wt pct Mn alloys containing 0.5 wt pct and 1 wt pct Nd have been processed by indirect extrusion at temperatures ranging from 548 K (275 °C) to 633 K (360 °C) and speeds between 2.8 and 11 mm/s. The microstructure and the texture of the extruded bars were analyzed in order to understand the effect of the processing parameters and of the rare-earth (RE) alloying additions on the texture development. Increasing the Nd content results in weak textures in which the predominant orientations are a function of the extrusion conditions. This may be explained by the occurrence of particle pinning of grain boundaries and by the nucleation of grains with a wider range of orientations. Mechanical tests were carried out in tension and in compression in all the processed samples at 10^?3 s^?1 and room temperature. It was found that larger RE amounts give rise to the disappearance of the yield asymmetry and to an anomalously high activity of tensile twinning, especially at the lowest extrusion temperatures. This has been attributed to an increase of the critical resolved shear stress of basal slip due to the presence of Mg₃Nd coherent and semi-coherent intermetallic prismatic plates.     

Product microstructures and properties induced by hot working a Pb-1.85 Pct Sb alloy

The concurrent effects of temperature and deformation on microstructure and mechanical properties of a 1.85 pct Sb lead alloy were examined by extrusion over the temperature range 0.7T _m to 0.9T _m, at deformation rates between 0.65 and 12 s^-1. Alloys deformed in the solid-solution regime or at the solvus temperature exhibited microstructures consisting of a mixture of elongated deformed grains and equiaxed recrystallized grains; some discontinuous precipitation was also evident. In the two-phase regime the structure was mainly fibrous; in this, the high resistance to recrystallization and the suppression of the discontinuous precipitation reaction could be attributed to the presence of fine precipitates in the dynamically formed substructure. A regime for providing optimum strength and stability was defined in the strain rate-temperature field investigated.     

Impurity effect on cube texture in pure aluminum foils

The effects of preheating temperature and annealing temperature after cold-rolling on the cube textures were studied on cold-rolled and recrystallized Al foils with different impurity contents. The density of the S-orientation in as-cold-rolled specimens is determined only by the preheating temperature and does not depend on the purity of the sample, whereas the texture of recrystallized samples is determined by both factors. In the highest purity sample (99.99 pct), a higher preheating temperature gives rise to a stronger cube texture. On the contrary, in less pure samples, a higher preheating temperature gives a weaker cube texture. This difference may be ascribed to the behavior of impurity atoms in the preheating process. Using Mössbauer spectroscopy, we have revealed the behavior of Fe atoms in Al foils subjected to the same heat and mechanical treatments and made clear the relation between the cube texture and the Fe concentration in the Al matrix.     

Microstructure and Mechanical Properties of Oxide-Dispersion Strengthened Al6063 Alloy with Ultra-Fine Grain Structure

The microstructure and mechanical properties of the ultra-fine grained (UFG) Al6063 alloy reinforced with nanometric aluminum oxide nanoparticles (25 nm) were investigated and compared with the coarse-grained (CG) Al6063 alloy (~2 μm). The UFG materials were prepared by mechanical alloying (MA) under high-purity Ar and Ar-5 vol pct O₂ atmospheres followed by hot powder extrusion (HPE). The CG alloy was produced by HPE of the gas-atomized Al6063 powder without applying MA. Electron backscatter diffraction under scanning electron microscopy together with transmission electron microscopy studies revealed that the microstructure of the milled powders after HPE consisted of ultra-fine grains (>100 nm) surrounded by nanostructured grains (<100 nm), revealing the formation of a bimodal grain structure. The grain size distribution was in the range of 20 to 850 nm with an average of 360 and 300 nm for Ar and Ar-5 pct O₂ atmospheres, respectively. The amount of oxide particles formed by reactive mechanical alloying under the Ar/O₂ atmosphere was ~0.8 vol pct, whereas the particles were almost uniformly distributed throughout the aluminum matrix. The UFG materials exhibited significant improvement in the hardness and yield strength with an absence of strain hardening behavior compared with CG material. The fracture surfaces showed a ductile fracture mode for both CG and UFG Al6063, in which the dimple size was related to the grain structure. A mixture of ductile–brittle fracture mode was observed for the UFG alloy containing 0.8 vol pct Al₂O₃ particles. The tensile behavior was described based on the formation of nonequilibrium grain boundaries with high internal stress and dislocation-based models.     

Mechanical Behavior of Al-SiC Nanocomposites Produced by Ball Milling and Spark Plasma Sintering

Al-SiC nanocomposites were prepared by high energy ball milling of mixtures of pure Al and 50-nm-diameter SiC nanoparticles, followed by spark plasma sintering. The final composites had grains of approximately 100 nm dimensions, with SiC particles located mostly at grain boundaries. The samples were tested in uniaxial compression by nano- and microindentation in order to establish the effect of the SiC volume fraction, stearic acid addition to the powder, and the milling time on the mechanical properties. The results are compared with those obtained for pure Al processed under similar conditions and for AA1050 aluminum. The yield stress of the nanocomposite with 1 vol pct SiC is more than ten times larger than that of AA1050. The largest increase is due to grain size reduction; nanocrystalline Al without SiC and processed by the same method has a yield stress seven times larger than AA1050. Adding 0.5 vol pct SiC increases the yield stress by an additional 47 pct, while the addition of 1 vol pct SiC leads to 50 pct increase relative to the nanocrystalline Al without SiC. Increasing the milling time and adding stearic acid to the powder during milling lead to relatively small increases of the flow stress. The hardness measured in nano- and microindentation experiments confirms these trends, although the numerical values of the gains are different. The stability of the microstructure was tested by annealing samples to 423 K and 523 K (150 °C and 250 °C) for 2 hours, in separate experiments. The heat treatment had no effect on the mechanical properties, except when treating the material with 1 vol pct SiC at 523 K (250 °C), which led to a reduction of the yield stress by 13 pct. The data suggest that the main strengthening mechanism is associated with grain size reduction, while the role of the SiC particles is mostly that of stabilizing the nanograins.     

The impact of cooling rates on the microstructure of Al-U alloys

The impact of cooling rates on the microstructure of Al-U alloys was studied by optical, scanning electron, and transmission electron microscopy. A variety of solidification techniques were employed to obtain cooling rates ranging between 3 × 10⁻² and 10⁶ K/s. High-purity uranium (99.9 pct) and high-purity aluminum (99.99 pct), or “commercially pure” type Al-1050 aluminum alloys were used to prepare Al-U alloys with U concentration ranging between 3 and 22 wt pct. The U concentration at which a coupled eutectic growth was observed depends on the cooling rates imposed during solidification and ranged from 13.8 wt pct for the slower cooling rates to more than 22 wt pct for the fastest cooling rates. The eutectic morphology and its distribution depends on the type of aluminum used in preparing the alloys and on the cooling rates during solidification. The eutectic in alloys prepared from pure aluminum was evenly distributed, while for those prepared from Al-1050, the eutectic was unevenly distributed, with eutectic colonies of up to 3 mm in diameter. Two lamellar eutectic structures were observed in alloys prepared from pure aluminum containing more than 18 wt pct U, which solidified by cooling rates of about 10 K/s. One structure consisted of the stable eutectic between UAl₄ and Al lamella. The other structure consisted of a metastable eutectic between UAl₃ and Al lamella. At least three different eutectic morphologies were observed in alloys prepared from Al-1050.     

Structure and properties of rapidly solidified 7075 P/M aluminum alloy modified with nickel and zirconium

Aluminum alloy 7075 was modified by additions of 1.1 wt pct nickel and 0.8 wt pct zirconium, rapidly solidified by ultrasonic gas atomization, canned, cold compacted, hot extruded, and evaluated in terms of structure and properties. Significant improvements in tensile strength (627 MPa YS and 680 MPa UTS) and crack growth rates were realized, along with a decrease in fracture toughness (23.7 MPa√m) while maintaining ductility (10 pct elong.) as compared to nominal I/M 7075 behavior. The stress for 10⁷ cycles fatigue life was greater than 275 MPa, which represents a 73 pct increase over that of I/M 7075. A variety of experiments was performed to evaluate effects on strength, ductility, and on structure. The variables were: powder size distribution, extrusion ratio, extrusion profile, different size fractions from the same lot of powder, and different locations of test bars in the several extrusions. Tensile properties, toughness, and fatigue properties were not importantly influenced by the location of test bars in the cross section or length of rectangular extruded bars. A comparison of mechanical properties from extruded bars prepared from ?53 μm powdersvs 53 to 250 μm powders showed a small loss of ductility and fatigue stress for 10⁷ cycles for the fine powder product. Higher extrusion ratios were beneficial for mechanical properties.     

Three-Point Bending of Heat-Treatable Aluminum Alloys: Influence of Microstructure and Texture on Bendability and Fracture Behavior

Three-point bending tests of extruded aluminum alloys showed lower bendability when the bending axis is aligned with the extrusion direction compared to the transverse direction. In the present work, three different microstructures of a commercial AA7108 aluminum alloy were studied with respect to mechanical properties, texture, constituent particles, and crack propagation. The three different microstructures were an as-cast and homogenized material, a fibrous extruded material, and a cold rolled and recrystallized material. While the mechanical properties in tension are more or less the same for the three materials, the bendability is strongly dependent on the microstructure and the global alignment of constituent particles. The as-cast and homogenized material shows poor bendability due to large grains and constituent particles on the grain boundaries, which leads to decohesion and premature failure. The response of both the fibrous and the recrystallized materials depends on the direction of the bending axis. A strong fiber texture is found to influence the bendability by initiation of shear bands. The crucial fracture mechanism, however, seems to be the global alignment of constituent particles, which is inherited from the deformation process.     

Evolution of surface recrystallization during indirect extrusion of 6xxx aluminum alloys

The fundamentals of coarse grain surface recrystallized structure formation in extrusion of 6xxx aluminum alloys are not yet completely understood. The objective of this article is to understand the metallurgical origins and mechanisms of the formation of the peripheral coarse grain (PCG) structure as the first step to understanding surface behavior of extruded aluminum alloys. Small-scale indirect extrusion tests were performed in which deformation parameters of strain, strain rate, and temperature were closely controlled. The deformed material was characterized via traditional metallography and orientation imaging microscopy (OIM) in order to understand the influence of processing conditions and alloy chemistry on surface grain formation. It was found that decreasing recrystallization-inhibiting elements such as Cr as well as increasing the starting extrusion temperature, extrusion ratio, and ram speed all increased the depth of the PCG. Additionally, a mechanism for favorable coarse grain formation at the surface of the extrudate is proposed based on microstructure development during extrusion.     

Effect of Icosahedral Quasicrystalline Fraction and Extrusion Ratio on Microstructure, Mechanical Properties, and Anisotropy of Mg-Zn-Gd-Based Alloys

We have fabricated three types of Mg-Zn-Gd-based alloys containing the icosahedral quasicrystalline phase (I-phase) to investigate how volume fraction of the I-phase and extrusion ratio can have an impact on the microstructure, mechanical properties, and anisotropy of the as-extruded alloys. We find that grains are refined and that the ultimate tensile strength and elongation are improved as either the volume fraction of I-phase or the extrusion ratio is increased, which can be attributed to the secondary phase particle stimulate recrystallization nucleation and restrained grain boundary motion. Moreover, anisotropy is mitigated in all of the alloys as either the I-phase fraction or the extrusion ratio is increased owing to the coeffect of texture weakening and grain refinement as well as to the effect of I-phase on twinning. We also find that with the increase in the amount of the I-phase, the yield strength (YS) is decreased for the alloys extruded at a low ratio owing to the texture weakening, yet it is increased for the alloys extruded at high ratio owing to the strengthening originating from the I-phase and refined grains. The mechanical properties are improved for the alloys extruded at high ratio, which is due to their fine grains and uniform microstructure.     

Microstructure and mechanical properties of ductile Ni3AI-type compound in Fe-(Ni,Mn)-AI-C systems rapidly quenched from melts

By the rapid quenching technique, nonequilibrium Ni₃Al-type compounds with high strength and hardness as well as large elongation have been found in Fe-Ni-Al-C and Fe-Mn-Al-C systems. This formation region is limited to about 7 to 55 wt pct Ni, 3 to 9 wt pct Al and 0.8 to 2.4 wt pct C for Fe-Ni-Al-C and to about 7 to 65 wt pct Mn, 3 to 9 wt pct Al and 0.8 to 2.4 wt pct C for Fe-Mn-Al-C. The Ni₃Al-type compound has fine grains of about 1 to 10 μm in diam. Their Vickers hardness and yield strength increase with increase in the amounts of carbon, aluminum or nickel and the highest values attain about 665 DPN and 1690 MPa for Fe-Ni-Al-C and 600 DPN and 1740 MPa for Fe-Mn-Al-C. Elongation increases with decrease in carbon or aluminum and attains about 11 pct for Fe-20 wt pct Ni-6 wt pct Al-1.2 wt pct C and 28 pct for Fe-20 wt pct Mn-8 wt pct Al-1.6 wt pct C. The good strength and ductility of the Ni₃Al-type compounds remain unchanged on tempering for 1 h until heated to about 750 K. Further, it has been found that the addition of chromium, molybdenum or cobalt is effective for the improvement of mechanical properties and thermal stability of the compounds. Thus, the use of materials containing Ni₃Al-type compounds may be attractive for fine gage high-strength wire or plate applications. Formerly Graduate Student of Tohoku University.     

Recrystallization in Commercially Pure Aluminum

Recrystallization behavior in commercial aluminum with a purity of 99.4 pct was studied by techniques such as high voltage electron microscopy, 100 kV transmission electron microscopy, and light microscopy. Sample parameters were the initial grain size (290 and 24 microns) and the degree of deformation (5 to 30 pct reduction in thickness by cold-rolling). It was found that the original grain boundary region is the preferred site for nucleation. A few intragranular nuclei were, however, also observed. The effectiveness of the nucleation sites is enhanced by the presence of intermetallic particles (FeAl₃), which start to become operative when the degree of deformation is raised from 15 to 30 pct. The temperature of nucleation and of recrystallization decreases when the degree of deformation is increased and the initial grain size is decreased. The recrystallized grain size follows the same trend and it is observed that the refinement of the recrystallized grain size caused by an increasing degree of deformation and decreasing initial grain size is enhanced by the FeAl₃ particles (when the degree of deformation is raised from 15 to 30 pct). Finally, the structural and kinetic observations are discussed and compared with results from an earlier study¹ covering the recrystallization behavior of commercial aluminum of the same purity deformed at higher degrees of deformation (50 to 90 pct reduction in thickness by cold-rolling).     

Texture Modification During Extrusion of Some Mg Alloys

The effects of extrusion ratio and alloying addition on the microstructure of Mg-0.2 wt pct Ce alloys are investigated by electron backscatter diffraction. The results show that in this alloy, texture randomization does not occur at high or low extrusion ratios but at a ratio of 25:1 at 400 °C. When extruded at the same temperature and extrusion ratio, Ca addition to Mg results in a weak nonbasal texture. In contrast, Mg-Al and Mg-3 wt pct Al-0.2 wt pct Ce alloys do not exhibit texture modification in single-pass extrusion. In the Mg-Al-Ce alloy, Ce and Al form Al₁₁Ce₃ particles, leaving little Ce solute in the matrix. The texture modifications in Mg-Ce or Mg-Ca alloys are related to the nature of the solid solution and consistent with dynamic strain aging during extrusion.