Dynamic recrystallisation and dynamic precipitation in AA6061 aluminium alloy during hot deformation

Abstract

Deformation behaviour of AA6061 alloy was investigated using uniaxial compression tests at temperatures from 400 to 500°C and strain rates from 0·01 to 1 s^?1. Stress increases to a peak value, then decreases monotonically until reaching a steady state. The dependence of stress on temperature and strain rate was fitted to a sinh-Arrhenius equation and characterised by the Zener–Hollomon parameter with apparent activation energy of 208·3 kJ mol^?1. Grain orientation spread analysis by electron backscattered diffraction indicated dynamic recovery and geometrical dynamic recrystallisation during hot compression. Deformation at a faster strain rate at a given temperature led to finer subgrains, resulting in higher strength. Dynamic precipitation took place concurrently and was strongly dependent on temperature. Precipitation of Q phase was found in the sample deformed at 400°C but none at 500°C. A larger volume fraction of precipitates was observed when samples were compressed at 400°C than at 500°C.     

Investigation of fatigue and fracture behaviour of sensitized marine grade aluminium alloy AA 5754

In the present study, fatigue and fracture characteristics of sensitized marine grade Al‐Mg (AA 5754) alloy are experimentally evaluated. Received alloy is sensitized at temperatures of 150°C (SENS50) and 175°C (SENS75) for 100 hours. Fracture parameters, K_Ic and J_Ic, are experimentally evaluated. Slow strain rate tensile tests at a crosshead speed of 0.004, 0.006, and 0.01 mm/min; fatigue crack growth tests at load ratios (R = P_min/P_max) of 0.1, 0.2, and 0.5; and low cycle fatigue tests at four strain amplitudes of (0.3‐0.6)% are performed for SENS50 and SENS75 alloys. Relatively lower magnitude of fracture toughness values are observed for SENS75 specimen. Severe degradation in tensile properties, fatigue crack growth characteristics, and low cycle fatigue lives are observed for SENS75 samples. Extended finite element method is adopted to simulate the elasto‐plastic crack growth during fracture toughness evaluation. Scanning electron microscopy (SEM) is used to understand the failure mechanism of sensitized alloys.     

Bending in aluminium alloys AA 6111 and AA 5754 using the cantilever bend test

Abstract

Bendability is an important forming parameter in many applications, but particularly in automotive parts where the formed parts in structures can be quite complex, and where outer skins are joined to inner panels through the hemming process. In this paper the bend performance of two aluminium based automotive alloys, the heat treatable skin alloy, AA 6111 and the non-heat treatable structural alloy AA 5754, are assessed by the cantilever bend test. This test enables the loadndash;bend angle relationship to be monitored, and provides a bend surface that can be examined for different bend angles, since the bending pin does not contact the specimen surface in the local region of the bend. The results demonstrate that the cantilever bend test can differentiate between different bend performance, and the differences relate to the damage process involved in bending. In the heat treatable AA 6111 the bendability is dependent on the alloy temper, which controls the bend angle at which large surface cracks appear on the surface. This fracture process is a result of differences in the development of surface topography and surface damage with bending strain. The AA 5754 alloy has similar behaviour, but the performance is superior to the best of the AA 6111 tempers, and reflects a lower rate of surface topography development, and an absence of significant surface cracking over the bend angle range investigated.     

Effect of recrystallisation on Al3Zr dispersoid behaviour in thick plates of aluminium alloy AA7150

The ageing responses of surface/centre layer materials from a commercially produced AA7150 thick plate have been studied after both water quenching (WQ) and air cooling (AC). The results show that the higher degree of recrystallisation near the plate surface decreases its age hardening response in AC condition. Quench-induced phases have been found to precipitate preferentially on Al₃Zr dispersoids in recrystallised grains. Microstructural observations show that Al₃Zr dispersoids in recrystallised grains exhibit the same crystal structure and orientation as those in adjacent subgrains.     

Laurus nobilis L. oil as green corrosion inhibitor for aluminium and AA5754 aluminium alloy in 3% NaCl solution

The influence of (30%, v/v) ethanolic solution of Laurus nobilis L. oil on the corrosion inhibition of aluminium and AA5754 aluminium alloy in 3% NaCl solution was studied by weight loss method, potentiodynamic polarization, and linear polarization method. The polarization measurements show that addition of this oil in concentrations ranging from 10 ppm to 50 ppm induces a decrease of cathodic currents densities. The results confirm that AA5754 alloy has better corrosion resistance in 3% NaCl solution than pure aluminium, while the oil investigated has better inhibition action on corrosion process of pure aluminium. The surface analysis via SEM techniques indicate that the active molecules from L. nobilis L. oil absolutely retard the pitting corrosion on the specimen surfaces.     

Microstructures and tensile properties of commercial purity aluminium alloy AA1235 under different annealing conditions

Microstructures, hardness, tensile properties and texture of cold-rolled AA1235 alloy are investigated under different annealing conditions. Precipitation of Al₃Fe particles occurs during annealing of the alloy. These precipitates largely affect the microstructural behaviour, tensile properties and texture of the alloy. After complete recrystallization no change in mechanical properties is observed upon further annealing.     

Influence of particles on recrystallisation textures and microstructures of aluminium alloy 3103

Abstract

The evolution of recrystallisation textures in the commercial aluminium alloy 3103 has been investigated by means of a three-dimensional orientation distribution function (ODF) analysis. The global texture measurements were supplemented by local texture measurements by means of the electron backscattering pattern (EBSP) technique in SEM and optical microscopy, inparticular grain size measurements. The evolution of recrystallisation textures was determined by the competition between particle stimulated nucleation (PSN) and nucleation from cube bands. Precipitated particles were found to have a higher retarding effect on the nucleation from deformation zones around particles than on the nucleation from cube bands. The result of this is a strong cube texture and a large grain size in cases of a strong precipitation reaction. This phenomenon has also been discussed theoretically in terms of a semiquantitative model.     

Kinetics of grain boundary segregation during recrystallisation annealing

Abstract

In batch annealing and continuous annealing processes, both recrystallisation and grain boundary segregation can occur. In this paper, a simple model is derived which explores the interaction of the boundary migration and segregation processes and considers the application to phosphorus segregation during the annealing of interstitial free steels. The model considers both segregation to a migrating boundary and the segregation which occurs during continuous cooling after the holding period during the anneal cycle.     

铝合金热变形组织演化的模拟

采用基于位错攀移及位错间交互作用的多元位错模型,对Al-Mg-Si(6005)合金热变形过程中亚晶内位错密度,亚晶界位错密度,可运位错位错密度及总的位错密度的演化进行了计算机模拟,并由此对Al-Mg-Si合金热压缩过程中的流变应力演化进行了预报,模拟结果和试验结果吻合较好,采用试验研究的方法建立了亚晶尺寸随变形条件演化的半经验关系模型,为铝合金热变形组织演化的预测和控制提供了实用模型。     

Inhomogeneous strain and recrystallisation of a shot-peened Inconel 625 alloy after annealing

Microstructural variations in a shot-peened nickel superalloy after isothermal annealing were observed via scanning electron microscopy and electron backscatter diffraction analysis. The analysis was based on inverse pole figure and kernel average misorientation maps. Before annealing, a heavily plastically deformed layer was observed under the surface. Post annealing for 1?h, the uppermost 30–40?µm layer was discontinuously recrystallised and inhomogeneous strains remained in the below layers. After a particular duration, the inhomogeneous strains recovered but did not recrystallise. The threshold depth of recrystallisation depended on the inhomogeneous strains. Recrystallisation and growth progressed from the recrystallisation-threshold depth toward the surface. These microstructural variations explain the release mechanism of the residual stress induced by shot peening.     

Ferrite recrystallisation and intercritical annealing of cold-rolled low alloy medium carbon steel

Static recrystallisation of cold-rolled AISI 4130 medium carbon steel in the ferritic regime and its response to intercritical annealing treatment are studied. A fine and recrystallised microstructure with improved mechanical properties is obtained via subcritical annealing of cold-rolled sheet, where the subsequent intercritical annealing results in the enhancement of tensile strength via the formation of dual-phase microstructure. Intercritical annealing of the cold-rolled sheet is characterised by an initial drop in hardness due to recrystallisation and subsequent rise in hardness as a result of austenitisation. It is revealed that continuous martensite phase can result in a higher deformation resistance. Finally, the effects of intercritical annealing at temperatures below pearlite dissolution finish temperature (Ac_1f) are discussed.     

Nature of the interface between AA7072 alloy explosively clad to AA8090 aluminium alloy

Aluminium-lithium based alloy plates were explosively clad with Al-1 wt% Zn alloy sheets. Clad plates were evaluated for bond continuity, interface shape, microstructure, variation of elemental concentrations across the bond interface, and bond strength. Comparisons of selected characteristics were made with roll clad sheets developed earlier.Ultrasonic tests revealed the bond to be continuous at all locations except over 50 mm wide edges of the plates. Both straight and wavy shaped interfaces were observed, often alternating arbitrarily. Microstructures on each side of the interface were distinct and characteristic of the individual alloys bonded. No localized melting was observed in the interface regions. Elemental concentration varied sharply across the bond line in the as-clad condition, later changing to a smooth profile after heat treatment. The diffusion widths, when expressed as a percentage of the cladding thickness, were much smaller than the corresponding values of previously studied roll clad sheets.'Tensile shear strength' of the clad samples exceeded the shear strength of monolithic Al-1%Zn alloy, thus indicating good bonding. The bond strength values were marginally lower than those of roll clad sheets. These differences could, perhaps, be due to the differences in the extent of elemental diffusion across the bond interface between the two techniques.     

Structure-property correlation on AA 2219 aluminium alloy weldments

AA 2219 aluminium alloy is the material proposed for the construction of tanks for liquid cryogenic fuels like liquid oxygen and liquid hydrogen, in Indian launch vehicle programmes. To meet the material requirement, ISRO has developed the alloy AA 2219 indigenously on an industrial scale. Process development and structure-property correlation of auto TIG weldments of AA 2219 Al alloy reported in this paper establishes that postweld reaging of AA 2219 weldments in T62 condition enhances both strength and ductility.     

Dynamic recrystallisation phenomena of commercial purity aluminium during friction welding

Abstract

The microstructures of commercial purity aluminium near the friction weld interface were observed by transmission electron microscopy. Large plastic deformation of aluminium occurred near the weld interface and the microstructure of the aluminium was oriented from the centre to the periphery of the weld nugget. The aluminium grains were refined, and there were many recrystallised grains which were almost dislocation free. The refined grains, which were of size ~ 1 νm, formed very near the weld interface. The grain boundary was estimated to be a large angle tilt boundary. The refined grains were mainly formed by dynamic recrystallisation during the upset stage of the welding cycle. A large amount of shear strain and heat were introduced during the friction stage, and dynamic recrystallisation started during the upset stage. Grain growth occurred during air cooling after the upset stage. The grain size was larger in the central region than in the periphery owing to the variation in temperature. The Vickers microhardness of aluminium near the weld interface increased owing to the microstructural refinement.     

Analysis of crack in aluminium alloy AA2219 weldment

Aluminium alloy AA2219 is used for fabrication of propellant tanks of launch vehicles. After welding of one of the heat treated plate (T87 temper condition) with a rolled ring (T851 temper condition), crack has been noticed near the weldment. A thorough metallographic analysis was carried out to investigate the cause for development of crack, using optical and scanning electron microscope. Morphology of cracks alongwith the attributable factors are discussed and the remedial measures are suggested.     

Transient liquid phase bonding of AA 6082 aluminium alloy

Transient liquid phase bonding (TLP) on AA 6082 samples were performed under ambient non‐vacuum conditions, which was possible by a suitable pre‐treatment. This treatment involves a zincate treatment followed by copper plating, which is a common industrial process and can be performed in large batches. This treatment allows to remove the natural aluminium oxide layer and to protect the aluminium surface from excessive oxidation. Different bonding conditions were investigated and showed the feasibility of the transient liquid phase bonding process for AA 6082. Energy dispersive X‐ray spectroscopy (EDX) investigations showed that the isothermal solidification is already terminated after 5 min. The microstructure of the bonding zone showed no metallurgical discontinuity such as eutectic microstructure or intermetallic Al–Cu phases. However the microstructure shows numerous voids with a size of approximately 30 µm in the bonding zone. It is assumed that these voids were formed during the bonding process due to solidification shrinkage and the presence of interfacial oxide layers. The transient liquid phase bonded samples that were mechanically tested under tensile load showed an average strength of approximately 270 MPa, the minimum yield strength required for the base material according to EN 754‐2 is 255 MPa. Due to the notch effect of the voids, the tensile sample failed under forced fracture and showed no plastic deformation.     

Numerical and experimental analysis of wrinkling during the cup drawing of an AA5042 aluminium alloy

The recent trend to reduce the thickness of metallic sheets used in forming processes strongly increases the likelihood of the occurrence of wrinkling. Thus, in order to obtain defect-free components, the prediction of this kind of defect becomes extremely important in the tool design and selection of process parameters. In this study, the sheet metal forming process proposed as a benchmark in the Numisheet 2014 conference is selected to analyse the influence of the tool geometry on wrinkling behaviour, as well as the reliability of the developed numerical model. The side-wall wrinkling during the deep drawing process of a cylindrical cup in AA5042 aluminium alloy is investigated through finite element simulation and experimental measurements. The material plastic anisotropy is modelled with an advanced yield criterion beyond the isotropic (von Mises) material behaviour. The results show that the shape of the wrinkles predicted by the numerical model is strongly affected by the finite element mesh used in the blank discretization. The accurate modelling of the plastic anisotropy of the aluminium alloy yields numerical results that are in good agreement with the experiments, particularly the shape and location of the wrinkles. The predicted punch force evolution is strongly influenced by the friction coefficient used in the model. Moreover, the two punch geometries provide drawn cups with different wrinkle waves, mainly differing in amplitude.     

Ageing and work-hardening behaviour of a commercial AA7108 aluminium alloy

In the 7xxx aluminium alloying system several mechanisms influence the hardening behaviour of the alloys, e.g. particle size and distribution, dislocation density and alloying elements in solid solution. This work is an experimental study of ageing and work-hardening considering a commercial AA7108 alloy in the as-cast and homogenized condition. Tensile specimens have been exposed to a solution heat treatment and a two-step age-hardening treatment with varying time at the final temperature. The tensile data for the different tempers have been evaluated in elucidation of already existing models based on a one-parameter framework. The precipitate size and distribution have been further investigated in the transmission electron microscope for a selection of tempers, and the influence of these parameters on the work-hardening behaviour has been discussed.     

Kinetics of precipitation hardening phase in aluminium alloy AA 6110

Abstract

The solid solution treated aluminium alloy AA 6110 was investigated using a differential scanning calorimetry (DSC) with different heating rates. Kinetic parameters, e.g. the activation energy and the Avrami exponent, were calculated. The peak temperatures of the hardening phase β″ from each heating rate were collected to calculate the activation energy of the aluminium alloy AA 6110 using various mathematical models: the Kissinger, Ozawa and Boswell models. It was found that the activation energies from each model were within the range of 106–114 kJ mol^?1. These activation energies were found to be lesser than those for the bulk diffusion of aluminium, magnesium and silicon atoms in aluminium matrix. The average Avrami exponent, n of 2·36 was calculated using the developed Matusita model and corresponded to a one-dimensional linear growth of fresh nuclei of needle-like β″ in this aluminium alloy AA 6110.     

Comparative investigations on numerical modeling for warm hydroforming of AA5754-O aluminum sheet alloy

This study aimed to determine the proper combinations of numerical modeling conditions (e.g. solver, element type, material model) for warm hydroforming of AA5754-O aluminum alloy sheets. Assessment of finite element analyses (FEA) is based on comparison of numerical results and experimental measurements obtained from closed-die forming, hydraulic bulge and tensile tests at different temperature (25–300 °C) and strain rate (0.0013–0.013 1/sec) levels. Thinning (% t) and cavity filling ratios (CFR) on the formed parts were taken as comparison parameters. Several numerical analyses employing different element types, solution methods and material models were performed using the commercially available FEA package LS-Dyna to determine the best combination of modeling options to simulate the actual warm hydroforming operation as accurately as possible. Analyses showed that relatively better predictions were obtained using isotropic material model, shell elements and implicit solution technique when compared with experimental results.