Creation of ultrafine-grained surfaces by large strain extrusion machining (LSEM)

Large strain extrusion machining (LSEM) is examined as a route for achieving controlled microstructure refinement at freshly generated surfaces in a single pass of the machining tool. It is shown that the extrusion ratio λ of LSEM, which is the ratio of the thickness of the chip to that of the preset depth of cut, controls the extent of the ultrafine-grained (UFG) zone. Microstructure analysis was performed using orientation imaging microscopy (OIM) and mechanical testing using nanoindentation was used to characterize the UFG microstructure beneath the freshly generated surfaces. The mechanics of deformation in LSEM were examined using infrared thermography and modeled. The present research demonstrates LSEM as a novel platform for tailoring surficial microstructures and controlling their spatial extents in fabricated components.