Grain refinement in magnetically stirred GTA welds of aluminum alloys

The mechanisms of grain refinement have been examined for magnetically stirred gas tungsten arc (GTA) welds completely penetrating thin sheets of several aluminum alloys. Grain refinement in unstirred welds may be brought about by adding sufficient titanium to produce heterogeneous nucleation by Ti-rich particles. In some alloys magnetic stirring is shown to extend the range of welding conditions which produce a partially equiaxed structure, and to widen the equiaxed fraction of partially equiaxed welds. This is attributed to magnetic stirring lowering the temperature gradient, allowing nucleation and growth of Al-rich grains further ahead of the columnar interface growing in from the fusion boundaries. In alloys with low Ti levels, magnetic stirring may cause refinement by sweeping grains from the partially molten zone ahead of the advancing solidification interface. This mechanism requires that the partially molten zone be sufficiently wide, and that the grain size in this zone remain small.     

Equal-channel angular pressing of commercial aluminum alloys: Grain refinement, thermal stability and tensile properties

Using equal-channel angular (ECA) pressing at room temperature, the grain sizes of six different commercial aluminum-based alloys (1100, 2024, 3004, 5083, 6061, and 7075) were reduced to within the submicrometer range. These grains were reasonably stable up to annealing temperatures of ∼200 °C and the submicrometer grains were retained in the 2024 and 7075 alloys to annealing temperatures of 300 °C. Tensile testing after ECA pressing through a single pass, equivalent to the introduction of a strain of ∼1, showed there is a significant increase in the values of the 0.2 pct proof stress and the ultimate tensile stress (UTS) for each alloy with a corresponding reduction in the elongations to failure. It is demonstrated that the magnitudes of these stresses scale with the square root of the Mg content in each alloy. Similar values for the proof stresses and the UTS were attained at the same equivalent strains in samples subjected to cold rolling, but the elongations to failure were higher after ECA pressing to equivalent strains >1 because of the introduction of a very small grain size. Detailed results for the 1100 and 3004 alloys show good agreement with the standard Hall-Petch relationship.     

Precipitate effects on the mechanical behavior of aluminum copper alloys: Part II. Modeling

This work focuses on a new hardening formulation accounting for precipitate-induced anisotropy in a binary aluminum-copper precipitation-hardened alloy. Different precipitates were developed upon aging at 190 °C and 260 °C, and corresponding work hardening characteristics were predicted for single and polycrystals. The use of single crystals facilitated the demonstration of the effect of precipitates on the flow anisotropy behavior. Pure aluminum was also studied to highlight the change in deformation mechanisms due to the introduction of precipitates in the matrix. The influence of precipitate-induced anisotropy on single-crystal flow behavior was clearly established, again relating to the precipitate character. Simulations are presented for several single-crystal orientations and polycrystals, and they display good agreement with experiments. The work demonstrates that precipitate-induced anisotropy can dominate over the crystal anisotropy effects in some cases.     

Precipitate effects on the mechanical behavior of aluminum copper alloys: Part II. Modeling

This work focuses on a new hardening formulation accounting for precipitate-induced anisotropy in a binary aluminum-copper precipitation-hardened alloy. Different precipitates were developed upon aging at 190°C and 260°C, and corresponding work hardening characteristics were predicted for single and polycrystals. The use of single crystals facilitated the demonstration of the effect of precipitates on the flow anisotropy behavior. Pure aluminum was also studied to highlight the change in deformation mechanisms due to the introduction of precipitates in the matrix. The influence of precipitate-induced anisotropy on single-crystal flow behavior was clearly established, again relating to the precipitate character. Simulations are presented for several single-crystal orientations and polycrystals, and they display good agreement with experiments. The work demonstrates that precipitate-induced anisotropy can dominate over the crystal anisotropy effects in some cases. T. FOGLESONG formerly with the Department of Mechanical and Industrial Engineering, University of Illinois, Urbana, IL 61801     

Wetting of ceramic particulates with liquid aluminum alloys: Part II. Study of wettability

Wetting phenomena in ceramic particulate/liquid Al-alloy systems were investigated experimentally using a new pressure infiltration technique developed by the authors. Studies were performed on two different ceramic particulates, SiC and B₄C, with four different liquid aluminum alloy matrices, pure Al, Al-Cu, Al-Si, and Al-Mg. Five major variables tested to study wetting phenomena in ceramic/Al-alloy systems were holding time, melt temperature, alloying element, gas atmosphere, and particulate. Metal: ceramic interfaces were investigated with optical microscopy, SEM, EPMA, and Auger Electron Spectroscopy (AES) in order to understand better the wetting process. The threshold infiltration pressure decreased with, temperature as well as with pressurization time for all the ceramic/metal systems. A strong correlation was found between the alloying effect on the threshold pressure and the free energy of formation of oxide phase of the alloying element. More reactive alloying elements were more effective in improving wettability. In air atmospheres, the threshold pressure usually increased markedly as a result of a thick oxide layer formation on the liquid front. Compacts of B₄C particulates showed lower threshold pressures than those of SiC, particulates. Fracture occurred in a generally brittle manner in infiltrated SiC, specimens. AES element profiles on the fracture surfaces showed fast diffusion of Si, and pile-up of C at the metal∶SiC boundaries which promoted fracture through the carbon-rich layer. The fracture surfaces of infiltrated B₄C specimens indicated plastic deformation, hence a more ductile failure mode.     

Study of the mechanism of grain refinement of aluminum after additions of Ti- and B-containing master alloys

A highly sensitive thermal analysis technique has been used to study the mechanisms of grain refinement in high-purity aluminum. Additions of Al-Ti-B master alloys were made both below and above the peritectic concentration in reference to the Al-rich corner of the binary Al-Ti phase diagram (0.15 pct Ti in solution). The experiments were conducted at various times after the addition of grain refiner. From the results, except for formation of TiB₂, no effect of boron on the Al-rich portion of the binary Al-Ti phase diagram can be observed. With hypoperitectic additions of Al-Ti-B master alloys, TiB₂ particles are the most frequent nucleant for aluminum grains. Also, when Al-5Ti-lB additions are made, nucleation frequently occurs above the equilibrium liquidus temperature. From a thermodynamic point of view, this phenomenon can occur only if regions of the melt (which contain bondes and nucleate new grains) have a higher Ti concentration than is present in the bulk of the liquid. A mechanism has been proposed to account for this observation. When hyperperitectic additions of grain refiner were made, a metastable formation of Al solid was often observed to occur at 2 to 5 deg above the equilibrium peritectic temperature. Other researchers have made this observation and proposed that a metastable aluminide phase was formed, even though no X-ray evidence of this phase was found. The experiments reported here show that the metastable nucleation occurs on boride particles when cooling from high temperature, which allow high (metastable) quantities of dissolved Ti to be retained in portions of the melt.     

Modeling of microporosity,macroporosity, and pipe-shrinkage formation during the solidification of alloys using a mushy-zone refinement method: Applications to aluminum alloys

A microporosity model, based on the solution of Darcy’s equation and microsegregation of gas, has been developed for arbitrary two- (2-D) and three-dimensional (3-D) geometry and coupled for the first time with macroporosity and pipe-shrinkage predictions. In order to accurately calculate the pressure drop within the mushy zone, a dynamic refinement technique has been implemented: a fine and regular finite volume (FV) grid is superimposed onto the finite-element (FE) mesh used for the heat-flow computations. For each time-step, the cells, which fall in the mushy zone, are activated, and the governing equations of microporosity formation are solved only within this domain, with appropriate boundary conditions. For that purpose, it is necessary to identify automatically the various liquid regions that may appear during solidification: open regions of liquid are connected to a free surface where a pressure is imposed, partially closed liquid regions are connected to an open region via the mushy zone, and closed regions are totally surrounded by the solid and/or mold. For partially closed liquid pockets, it is shown that an integral boundary condition applies before macroporosity appears. Finally, pipe shrinkage (i.e., shrinkage appearing at a free surface) is obtained by integration of the calculated interdendritic fluid flow over the open-region boundaries, thus ensuring that the total shrinkage (microporosity plus macroporosity and pipe shrinkage) respects the overall mass balance. This very general approach is applied to Al-Cu and Al-Si alloys.     

Electromagnetic refining of aluminum alloys by the CREM process: Part II. Specific practical problems and their solutions

An experimental investigation, described in Part I and bearing on aluminum alloy billets produced by the CREM process, has shown that the main characteristics of this new technology are the elimination of the need for grain-refiner master alloys and a marked reduction of the scalping operation. Part II reports on the examination of the problems specific to the CREM process, which occur particularly during slab casting. The three-dimensional (3-D) aspect of the electromagnetic and fluid flow phenomena, the effect of the electrical conductivity of the ingot mold, and the improvement of the process design are examined.     

Calorimetric studies of 7000 series aluminum alloys: II. Comparison of 7075, 7050 and RX720 alloys

Differential scanning calorimetry (DSC) in conjunction with transmission electron microscopy (TEM) are used to characterize the matrix precipitate structure of high strength and overaged tempers of three 7000 series aluminum alloys. Excellent consistency exists between the DSC results, based on the dissolution behavior of existing precipitates, and TEM observations. Comparison is made between matrix precipitate constituency and mechanical properties. A significantly high GP zone particle density was observed in a high strength 7050 alloy temper, but this temper did not have higher strength than other predominantly GP zone matrix tempers. Maximum strength was observed in a 7050 alloy temper that contained approximately equal amounts of GP zones and ή phase precipitates. Strengthening appears to be based on the contribution of both coherent GP zones and semicoherent ή precipitates. Use of the DSC approach and the free energy of activation for precipitate dissolution are recommended as rapid and quantitative means of precipitate identification.     

Grain boundary precipitation in aluminum alloys: Effect of boundary structure

A transmission electron microscope study of grain boundary precipitation in Al-Zn and Al-Zn-Mg alloys has been conducted with emphasis on the influence of localized boundary structure. Intrinsic grain boundary defects are found to have a significant effect on the precipitation sequence in that they assist the emerging precipitates in establishing a low energy habit plane relationship with at least one bordering grain. Under more extreme conditions of unavailable habits or unfavorable intrinsic structures, extrinsic defects dominate the precipitation reaction.     

Deformation and fracture of a particle-reinforced aluminum alloy composite: Part II. Modeling

In this article, the tensile and fracture properties of a discontinuously reinforced aluminum (DRA) alloy composite are modeled to determine the influence of constituent parameters on material behavior. Comparison of the elastic-modulus calculations to the experimental data suggest that the angular particles are more effective in load transfer than spherical particles, and that a unit cylinder geometry is a good representation of the particles under elastic conditions. This same geometry is used in the finite element-based elastic-plastic model of Bao et al., and reasonably good agreement is obtained between the experimental and predicted yield strengths. A fracture-mechanics model is proposed for predicting the elongation to failure. The model assumes the existence of particle cracks, and criticality is based on the strain required for matrix rupture between cracked particles. The damage criterion of Cockcroft and Latham is utilized, and model predictions are compared to data from different investigations. It is shown that the volume fraction of particles and the work-hardening coefficient of the matrix have a strong influence on the strain to failure. Fracture toughness modeling one again exposes the limitations of existing zero-degree crack-propagation models, such as that of Hahn and Rosenfield, which predict increased toughness with yield strength rather than a decrease, which is observed experimentally. A shear-failure model along a 45-deg direction is proposed for the higher-strength conditions, where concentrated slip bands were observed. The model exhibits the inverse toughness dependence on strength and better correlation to peak-aged (PA) data, but shows poorer agreement with underaged (UA) data. Thus, a transition from zero-degree propagation to 45-deg propagation with increasing strength is suggested. A simplified method for extracting particle stresses is illustrated and is used to estimate a Weibull modulus of 4.9 and a Weibull strength of 2450 MPa for the SiC particles of an average diameter of 10 μm. This article is based on a presentation made in the Symposium “Mechanisms and Mechanics of Composites Fracture” held October 11–15, 1998, at the TMS Fall Meeting in Rosemont, Illinois, under the auspices of the TMS-SMD/ASM-MSCTS Composite Materials Committee.     

Deformation and fracture of a particle-reinforced aluminum alloy composite: Part II. Modeling

In this article, the tensile and fracture properties of a discontinuously reinforced aluminum (DRA) alloy composite are modeled to determine the influence of constituent parameters on material behavior. Comparison of the elastic-modulus calculations to the experimental data suggest that the angular particles are more effective in load transfer than spherical particles, and that a unit cylinder geometry is a good representation of the particles under elastic conditions. This same geometry is used in the finite element-based elastic-plastic model of Bao et al., and reasonably good agreement is obtained between the experimental and predicted yield strengths. A fracture-mechanics model is proposed for predicting the elongation to failure. The model assumes the existence of particle cracks, and criticality is based on the strain required for matrix rupture between cracked particles. The damage criterion of Cockcroft and Latham is utilized, and model predictions are compared to data from different investigations. It is shown that the volume fraction of particles and the work-hardening coefficient of the matrix have a strong influence on the strain to failure. Fracture toughness modeling once again exposes the limitations of existing zero-degree crack-propagation models, such as that of Hahn and Rosenfield, which predict increased toughness with yield strength rather than a decrease, which is observed experimentally. A shear-failure model along a 45-deg direction is proposed for the higher-strength conditions, where concentrated slip bands were observed. The model exhibits the inverse toughness dependence on strength and better correlation to peak-aged (PA) data, but shows poorer agreement with underaged (UA) data. Thus, a transition from zero-degree propagation to 45-deg propagation with increasing strength is suggested. A simplified method for extracting particle stresses is illustrated and is used to estimate a Weibull modulus of 4.9 and a Weibull strength of 2450 MPa for the SiC particles of an average diameter of 10 μm. This article is based on a presentation made in the Symposium “Mechanisms and Mechanics of Composites Fracture” held October 11–15, 1998, at the TMS Fall Meeting in Rosemont, Illinois, under the auspices of the TMS-SMD/ASM-MSCTS Composite Materials Committee.     

Modeling the microstructural changes during hot tandem rolling of AA5XXX aluminum alloys: Part II. Textural evolution

In Part II of this article, the experimental work undertaken to measure the effect of deformation parameters (temperature, strain, and strain rate) on the texture formation during hot deformation and the evolution during subsequent recrystallization is described. In addition, the isothermal kinetics of development of individual texture components were also determined. A neutron diffractometer was used to measure the texture in the as-hot-deformed aluminum samples, and the samples were then heat treated in a 400 °C salt bath for various lengths of time, with the texture being remeasured at various stages in the recrystallization process. Using data from the experimental program, the texture evolution during recrystallization was modeled by applying a modified form of the Avrami equation. Results indicated that, of the deformation parameters studied, textural development was most sensitive to the deformation temperature for both alloys. In addition, modeling results revealed that the Cu component ({112} 〈111〉) was the first to recrystallize, typically followed by the S ({123} 〈634〉) and Bs ({110} 〈112〉) components. This is in agreement with earlier work which indicated that the Bs component was the hardest to recrystallize, possibly because it is able to deform on very few slip systems and, hence, the dislocation interaction may be low.     

Forging limits for an aluminum matrix composite: Part II. Analysis

Plasticity analysis has been carried out to calculate the forging limits of a particulate-reinforced aluminum matrix composite under various forging conditions. A geometric defect(i.e., variation in cross-sectional area) that can concentrate stresses and strain and accelerate local deformation was assumed to represent all possible defects in this material. Thus, in effect, the local stress concentrations around nondeformable particles, inhomogeneous distribution of particles and grain sizes, porosity and cracked particles,etc., were assumed to be simulated adequately by such a defect factor. The analysis followed a method suggested by Marciniak and Kuczynski (MK) to determine the strain path within the defect region of the composite during multiaxial deformation. A relationship of stress, strain, and strain rate obtained from the uniaxial tension test was used for the calculation of the strains. To terminate the plasticity analysis, a rateindependent fracture criterion was used that is based on Cockcroft’s model of a constant work performed by the tensile component of stress. It was found that the calculated results predicted the experimental forging limits for 2014 Al/15 vol pct A1₂O₃ reasonably well. At 400 °C and a slow strain rate (0.015 s~’), the predicted curve was higher than the experimental result. This was probably because the fracture mechanism, and thus fracture criterion, changed with temperature. The effect of assumed defect factor on predicted forging limits was also studied. It was found that the size of the defect factor did not significantly change the forging limits at 300 °C for strain rates from 0.015 s to 0.5 s^-1; however, it did have a large effect on the forging limit at 400 °C for the lower strain rate of 0.015 s^-1. Formerly Graduate Student, the University of Michigan     

Heat transport and solidification in the electromagnetic casting of aluminum alloys: Part II. Development of a mathematical model and comparison with experimental results

In this second article of a two-part series, a mathematical model for heat transport and solidification of aluminum in electromagnetic casting is developed. The model is a three-dimensional one but involves a simplified treatment of convective heat transport in the liquid metal pool. Heat conduction in the solid was thought to play a dominant role in heat transport, and the thermal properties of the two alloys used in measurements reported in Part I (AA 5182 and 3104) were measured independently for input to the model. Heat transfer into the water sprays impacting the sides of the ingot was approximated using a heat-transfer coefficient from direct chill casting; because this heat-transfer step appears not to be rate determining for solidification and cooling of most of the ingot, there is little inaccuracy involved in this approximation. Joule heating was incorporated into some of the computations, which were carried out using the finite element software FIDAP. There was good agreement between the computed results and extensive thermocouple measurements (reported in Part I) made on a pilot-scale caster at Reynolds Metals Company (Richmond, VA).     

New methods for the determination of hydrogen content of aluminum and its alloys: Part II. Rapid determination by the nitrogen carrier fusion method

A method for determining hydrogen in steel by melting with nitrogen as a carrier gas was adapted for aluminum and its alloys. Dehydrogenationvs temperature was investigated in order to define an optimal sequence of operating conditions. The results obtained by the method were systematically compared to those given by the reference vacuum hot extraction method. The essential characteristics of this new method can be summarized as follows: 1) The detection limit is 0.02 ml/100 g (0.02 ppm H₂). 2) The method is valid for any alloy, even for those with high volatile constituent content such as Zn or Mg. 3) The bulk hydrogen content is not significantly different from that given by the vacuum hot extraction method. 4) “Surface” hydrogen could be eliminated by a thermal treatment at 400°C prior to melting. 5) Correlations appeared between changes in thermal and dehydrogenation curves, the last one representing a characteristic spectrum of the alloy studied. 6) A complete analysis requires 15 min instead of several hours for the hot extraction method. It is thus applicable in routine industrial work.     

Precipitate effects on the mechanical behavior of aluminum copper alloys: Part I. Experiments

This article focuses on understanding the mechanical behavior of precipitation-hardened alloys by studying single and polycrystalline deformation behavior with various heat treatments. Aluminumcopper alloys are the focus in this work and their changing stress-strain behavior is demonstrated resulting from the different hardening mechanisms brought about by the various precipitates. Extensive transmission electron microscopy investigations facilitated the interpretation of the stress-strain behavior and the work hardening characteristics. The use of both single and polycrystals proved valuable in understanding the role of anisotropy due to crystal orientation vs precipitate-induced anisotropy. The experiments show that precipitation-induced anisotropy could offset the crystal orientation anisotropy depending on the orientation. This is clearly demonstrated with similar [111] and [123] behaviors under 190 °C and 260 °C aging temperatures. Experiments on pure aluminum crystals are also provided for comparison and understanding the crystal anisotropy in the absence of precipitates. Part I of this article will focus on experiments, and part II will describe the modeling of the effect of different metastable phases in the matrix acting as barriers to dislocation motion.     

Precipitate effects on the mechanical behavior of aluminum copper alloys: Part I. Experiments

This article focuses on understanding the mechanical behavior of precipitation-hardened alloys by studying single and polycrystalline deformation behavior with various heat treatments. Aluminumcopper alloys are the focus in this work and their changing stress-strain behavior is demonstrated resulting from the different hardening mechanisms brought about by the various precipitates. Extensive transmission electron microscopy investigations facilitated the interpretation of the stress-strain behavior and the work hardening characteristics. The use of both single and polycrystals proved valuable in understanding the role of anisotropy due to crystal orientation vs precipitate-induced anisotropy. The experiments show that precipitation-induced anisotropy could offset the crystal orientation anisotropy depending on the orientation. This is clearly demonstrated with similar [111] and [123] behaviors under 190 °C and 260 °C aging temperatures. Experiments on pure aluminum crystals are also provided for comparison and understanding the crystal anisotropy in the absence of precipitates. Part I of this article will focus on experiments, and part II will describe the modeling of the effect of different metastable phases in the matrix acting as barriers to dislocation motion. FOGLESONG for-merly with the Department of Mechanical and Industrial Engineering, University of Illinois, Urbana, IL 61801