The significance of grain boundary sliding in the superplastic Zn–22 % Al alloy processed by ECAP

A Zn–22 % Al eutectoid alloy was processed by equal-channel angular pressing (ECAP) to reduce the grain size to ~0.8 μm. Tensile testing at 473 K showed superplastic characteristics with a maximum elongation of ~2230 % at a strain rate of 1.0 × 10^?2 s^?1. The significance of grain boundary sliding (GBS) was evaluated by measuring sliding offsets at adjacent grains from the displacements of surface marker lines in samples pulled to elongations of 30 % at a series of different strain rates. The highest sliding contribution was recorded under testing conditions corresponding to the maximum superplastic ductility. There were relatively large offsets at the Zn–Zn and Zn–Al interfaces, but smaller offsets at the Al–Al interfaces. Analysis shows the results are affected by the presence of agglomerates of similar grains which are present after ECAP processing and specifically by the increased fraction of Al–Al boundaries. The experimental results are in excellent agreement with the predictions of a deformation mechanism map depicting the flow behavior in the Zn–22 % Al alloy, and the results confirm the importance of GBS as the dominant mechanism of flow in superplasticity after processing by ECAP.     

Achieving superplastic properties in a Pb–Sn eutectic alloy processed by equal-channel angular pressing

Experiments were conducted on a Pb-62% Sn eutectic alloy containing 160 ppm of Sb. The alloy was processed by equal-channel angular pressing (ECAP) through 1 to 5 passes at room temperature and then tested in tension at a temperature of 423 K using initial strain rates from 1.0 × 10⁻⁴ to 1.0 × 10⁻¹ s⁻¹. Excellent superplastic elongations were achieved at intermediate strain rates with a maximum elongation to failure of 2,665%. It is shown that, for processing through similar numbers of ECAP passes, these elongations are higher than in an earlier investigation using a Pb-62% Sn alloy of higher purity. The results are presented pictorially in the form of a deformation mechanism map by plotting normalized grain size against normalized stress at a temperature of 423 K.     

Effect of aging on microstructural development in an Al–Mg–Si alloy processed by high-pressure torsion

Experiments were conducted to evaluate the microstructural evolution in a commercial Al-0.6 % Mg-0.4 % Si alloy processed using high-pressure torsion for up to 20 turns. Disks of the alloy were tested in two different conditions: in a solution-treated condition and after a short aging treatment at 523 K. The results show that HPT processing introduces significant grain refinement through HPT processing including a reduction in grain size from ~150 μm to ~720 nm in 1 turn of HPT. The final grain size in this alloy was ~250 nm after 20 turns. Some tensile tests were conducted to evaluate the mechanical properties of the alloy at the solution treatment temperature. The results from these tests show that aging at 523 K leads to a small increase in ductility for all tensile samples with a maximum recorded elongation of ~230 %.     

Achieving homogeneity in a Cu–Zr alloy processed by high-pressure torsion

A copper alloy, Cu–0.1 %Zr, was subjected to severe plastic deformation at room temperature using quasi-constrained high-pressure torsion. Disks were strained through different numbers of revolutions up to a maximum of ten turns under an applied pressure of 6.0 GPa and then examined to evaluate the evolution in the Vickers microhardness, Hv, and the microstructure. The results show lower values of Hv in the center regions of the disks in the early stages of processing but a gradual evolution to a high degree of hardness homogeneity after five and ten turns. Under conditions of hardness homogeneity, the distributions of the grain boundary misorientations are essentially identical at the center and the periphery of the sample. Homogeneity was further confirmed by conducting tensile testing at elevated temperatures where similar stress–strain curves and similar elongations to failure were recorded after processing through five and ten turns of HPT.     

Microstructural evolution and superplastic behavior in friction stir processed Mg–Li–Al–Zn alloy

A Mg–Li–Al–Zn alloy was friction stir processed (FSP) under water, and the microstructures and superplastic behavior in the FSP alloy were investigated. The FSP Mg–Li–Al–Zn alloy consisted of a mixed microstructure with fine, equiaxed, and recrystallized α (hcp) and β (bcc) grains surrounded by high-angle grain boundaries, and the average grain size of the α and β grains was ~1.6 and ~6.8 μm, respectively. The fine α grains played a critical role in providing thermal stability for the β grains. The FSP Mg–Li–Al–Zn alloy exhibited low-temperature superplasticity with a ductility of 330 % at 100 °C and high strain rate superplasticity with ductility of ≥400 % at 225–300 °C. Microstructural examination and superplastic data analysis revealed that the dominant deformation mechanism for the FSPed Mg–Li–Al–Zn alloy is grain boundary sliding, which is controlled by the grain boundary diffusion in the β phase.     

The fatigue damage development in a cast Al–Si–Cu alloy

The experimental identification of fatigue damage mechanisms and evaluation of their development rate, based on changes in material respond on cycle loading, has been presented in the work. The research has been conducted on hyper-eutectic cast alloy AlSi8Cu3. The microstructure and fracture analyses were performed. The high cycle fatigue tests were conducted with frequency of 20 Hz under constant nominal stress amplitude with monitoring the strain response of material during the test. The ratcheting was found as the main mechanism of the fatigue damage. It was established that the linear fatigue accumulation law should not be used for fatigue life prediction in case of the tested cast aluminum alloy.     

Development of a high strain rate superplastic Al–Mg–Zr alloy

Abstract

For superplastic forming of aluminium to break out of the niche market that it currently occupies, alloys will be required to possess a higher strain rate capability, appropriate in service properties, and a significantly lower price and to be capable of volume production. This paper describes an approach that has been developed in an attempt to address these fundamental requirements. A series of Al–Mg–Zr alloys with increasing levels of zirconium (0–1 wt-%)has been prepared via extrusion consolidation of cast particulate (solidification rate ～10³ K s^-1). The superplastic properties of the resultant cold rolled sheet have been evaluated as a function of thermomechanical treatment and zirconium addition. It has been found that increasing the level of zirconium has the twofold effect of improving the superplastic properties of the alloy while significantly decreasing the concomitant flow stress. At present the optimum superplastic behaviour has been obtained at strain rates of 10^-2 s^-1, with the 1%Zr material exhibiting ductilities in excess of 600%. The manufacturing route produces a bimodal distribution of Al₃Zr comprising >1 µm primary particles in combination with nanoscale solid state precipitates. The current postulation is that this high strain rate superplasticity is conferred by a combination of particle stimulated and strain induced recrystallisation.     

Effect of strain on cavity development during Al–Zn–Mg–Cu alloy superplastic flow

Cavitation behaviour has been investigated in an Al–Zn–Mg–Cu alloy with an average grain size of 10?µm during superplastic deformation. The superplastic tensile tests were interrupted at different true strains at 530°C and 3?×?10^?4?s^?1. The results showed that cavity nucleation occurred above a critical strain in the optimum loading condition. It was easy for cavities to form at the triple junction due to the stress concentration caused by cooperative grain boundary sliding. Since the tensile stress was higher in the middle of the sample, the cavities were arranged in a straight line parallel to the tensile axis in the centre of the sample. A more appropriate cavity growth equation considering the critical strain was proposed to describe the cavitation behaviour.     

The role of microstructure of nickel–aluminium–bronze alloy on its cavitation corrosion behavior in natural seawater

An investigation was carried out in our laboratory to study the effect of the microstructure of nickel–aluminum–bronze (NAB) alloy on its cavitation corrosion behaviour in seawater using a 20-kHz ultrasonic induced cavitation facility. Cavitation tests were made under free corrosion conditions as a function of exposure time in natural seawater. Optical and scanning electron microscopy showed NAB immersed in stagnant seawater suffered from selective corrosion of the copper-rich α phase at boundaries with intermetallic κ precipitates. The κ precipitates and precipitate-free zones did not suffer corrosion. Cavitation made the surface of this alloy very rough, with large cavities or pits, ductile tearing and corrosion of the boundaries of the α columnar grains. In addition, the number of cavities and their size increased with exposure time. Microcracks 5–10 μm long were observed in the α phase adjacent to κ precipitates along the cross-section of the material. Selective phase corrosion and cavitation stresses were considered to be the cause of the cracks observed.     

Mechanism of zinc oxide–aluminum aluminothermic reaction

In this study, the aluminothermic reaction of a mixture of aluminum and zinc oxide powders ball milled at ambient temperature was investigated employing X-ray diffraction (XRD), differential thermal analysis (DTA), and electron microscopy (SEM) techniques. The kinetics of the reaction was studied based on DTA results to evaluate the mechanism and the activation energy of the reaction. The reaction mechanism was recognized to be an interface controlled one. The activation energy as well as the ignition temperature of the aluminothermic reaction was found to decrease significantly with increasing the milling time. The ignition temperature of the reaction was reduced from 1008 °C for the unmilled mixture to 563 °C for the mixture milled for 60 min. This was rationalized in terms of the microstructural changes observed in the milled mixtures. The activation energy also decreased from 848 kJ/mol for the unmilled mixture to 119 kJ/mol for the mixture milled for 60 min.     

Microstructure evolution and mechanical properties of a Ti–35Nb–3Zr–2Ta biomedical alloy processed by equal channel angular pressing (ECAP)

In this paper, an equal channel angular pressing method is employed to refine grains and enhance mechanical properties of a new β Ti–35Nb–3Zr–2Ta biomedical alloy. After the 4th pass, the ultrafine equiaxed grains of approximately 300 nm and 600 nm are obtained at pressing temperatures of 500 and 600 °C respectively. The SEM images of billets pressed at 500 °C reveal the evolution of shear bands and finally at the 4th pass intersectant networks of shear bands, involving initial band propagation and new band broadening, are formed with the purpose of accommodating large plastic strain. Furthermore, a unique herringbone microstructure of twinned martensitic variants is observed in TEM images. The results of microhardness measurements and uniaxial tensile tests show a significant improvement in microhardness and tensile strength from 534 MPa to 765 MPa, while keeping a good level of ductility (~ 16%) and low elastic modulus (~ 59 GPa). The maximum superelastic strain of 1.4% and maximum recovered strain of 2.7% are obtained in the billets pressed at 500 °C via the 4th pass, which exhibits an excellent superelastic behavior. Meanwhile, the effects of different accumulative deformations and pressing temperatures on superelasticity of the ECAP-processed alloys are investigated.     

The development of microstructural damage during high temperature creep–fatigue of a nickel alloy

Alloy 617 is the leading candidate material for an Intermediate Heat Exchanger (IHX) of the Very High Temperature Reactor (VHTR). To evaluate the behavior of this material in the expected service conditions, strain-controlled cyclic tests that include hold times up to 9000 s at maximum tensile strain were conducted at 950 °C. The fatigue resistance decreased when a hold time was added at peak tensile strain, owing to the mechanisms resulting in a change in fracture mode from transgranular in pure fatigue to intergranular in creep–fatigue. Increases in the tensile hold duration beyond an initial value were not detrimental to the creep–fatigue resistance. An analysis of the evolving failure modes was facilitated by interrupting tests during cycling for ex situ microstructural investigation.     

The effect of strontium on the mechanical properties of aluminum–silicon alloy

Technical Physics Letters - We have studied the influence of strontium additives on the microstructure and mechanical properties of an aluminum alloy with 15 wt % silicon prepared by directional...     

Precipitation hardening and grain refinement in an Al–4.2wt%Mg–1.2wt%Cu processed by ECAP

The precipitation and the strength evolution during equal channel angular pressing performed at 180 °C in an Al–4.2wt% Mg–1.2wt%Cu alloy have been studied by room temperature compression tests and transmission electron microscopy. The age hardening behaviour of these AlMgCu alloys, in which the precipitation sequence involves the S-phase and its precursors, was investigated and revealed a yield strength peak after 8 days at 180 °C. The influence of the Severe Plastic Deformation on the microstructure and mechanical properties of under-aged and peak-aged samples are presented. Notably, in the under-aged sample, a gradual increase of the strength after each ECAP pass is obtained while, the peak-aged samples loose much of their strength during the first ECAP pass. TEM characterization of the microstructure before and after ECAP is presented and linked to the evolution of the mechanical properties.     

Microstructure and properties of Cu–Mg alloy treated by internal oxidation

A Cu–0.24Mg alloy bar was treated by internal oxidation using Cu₂O as an oxidiser at 1123–1273?K for 10?h. The thermodynamic diagram for oxidation of a Cu–Mg alloy was confirmed by the critical oxygen pressure. The results show that the thickness of the MgO/Cu layer and the electrical conductivity of the Cu–0.24Mg alloy increase with increasing internal oxidation temperature, whereas the average hardness of the MgO/Cu layer initially increases and subsequently decreases. Examination of the microstructure of the MgO/Cu layer revealed that Mg precipitation in the form of MgO particles and their uniform dispersion in the Cu matrix were the primary reasons for increases in the comprehensive properties of the Cu–Mg alloy treated by internal oxidation.     

Microstructural evolution and microhardness variations in a Cu–36Zn–2Pb alloy processed by high-pressure torsion

A coarse-grained Cu–36Zn–2Pb alloy with an initial grain size of ~54 μm was processed by high-pressure torsion (HPT) at room temperature under an applied pressure of 6.0 GPa through 1–10 turns, and the evolution of microstructure and microhardness was investigated. Analysis by X-ray diffraction (XRD) showed that in HPT processing the β′-phase transforms to an α-phase and a {111} texture is formed. Microscopic examination showed that dislocations were first formed at equivalent strains of not more than ~25 and when the equivalent strain increased to ~40 there was evidence for twins and secondary twinning. Fine grains were formed with an increase in equivalent strain to ~100 and with further straining these refined grains acted as precursors for additional grain refinement. The refined equiaxed grain size was ~250 nm after HPT through an equivalent strain of ~100 and the results show the microhardness reached a saturation value of ~220 Hv.