Search Results (57)

We report a scalable route to hybrid aluminum matrix composites (AMCs) based on Al6060 (as-fabricated condition) reinforced with 2 wt.% TiB₂ and 1 wt.% microsilica, fabricated by ultrasonically assisted stir casting (UASC) followed by radial-shear rolling (RSR). Premixing and preheating of powders combined with acoustic cavitation/streaming during UASC ensured uniform, non-sedimentary particle dispersion and low-defect cast billets. X-ray diffraction of the as-cast composite shows fcc-Al with weak TiB₂ reflections and no reaction products; microsilica remains amorphous. Electron microscopy and EBSD after RSR reveal full erasure of cast dendrites, fine equiaxed grains, weakened texture, and a high fraction of high-angle boundaries due to the concurrent action of particle-stimulated nucleation (micron-scale TiB₂) and Zener pinning/Orowan strengthening (50–350 nm microsilica). Mechanical testing shows that, in the cast state—comparing cast monolithic Al6060 to the cast hybrid-reinforced composite—yield strength (YS) increases from 61.7 to 77.2 MPa and ultimate tensile strength (UTS) from 103.4 to 130.7 MPa, without loss of ductility. After RSR to Ø16 mm (cumulated true strain ≈ 0.893), the hybrid attains YS 101.2 MPa, UTS 150.6 MPa, and elongation ≈ 22.0%, i.e., comparable strength to rolled Al6060 (UTS 145.1 MPa) while restoring/raising ductility by ~9.7 percentage points. Microhardness follows the same trend, increasing from 50.2 HV0.2 to 73.1 HV0.2 when comparing the base cast condition with the rolled hybrid. The route from UASC to RSR thus achieves a favorable mechanical strength–ductility balance using an economical, eco-friendly oxide/boride hybrid reinforcement, making it attractive for formable AMC bar and rod products. Full article

Lightweight magnesium alloys are gaining increasing attention as potential structural materials for automotive and aerospace applications due to their high specific strength and excellent recyclability. However, their formability and mechanical performance are often limited by strong basal texture and limited recrystallization during thermomechanical processing. In this context, the present study systematically investigates the effect of post-annealing treatment on the microstructural evolution, recrystallization behavior, and mechanical response of a hot-rolled Mg-3Al-1Zn-1Ca alloy. Detailed microstructural characterization revealed that Al₂Ca precipitates were uniformly distributed along grain boundaries in the as-received (AR) condition, where they contributed to significant pinning of boundary migration. Post-annealing treatment (350 °C, furnace cooling) resulted in non-uniform grain coarsening, driven by the interplay of precipitate pinning and differential stored strain energy, while also facilitating particle-stimulated nucleation (PSN) and recrystallization. Electron backscatter diffraction (EBSD) analysis confirmed a substantial increase in the fraction of high-angle grain boundaries and recrystallized grains in the heat-treated (HT) state, with kernel average misorientation (KAM) and grain orientation spread (GOS) analyses indicating pronounced recovery of lattice distortions. Mechanical testing demonstrated a significant decrease in yield strength (263 MPa to 187.4 MPa) and hardness (65.7 to 54.1 HV) due to dislocation annihilation and stress relaxation, while ultimate tensile strength remained nearly unchanged (~338 MPa) and ductility improved markedly (12.6% to 16.4%). These findings highlight the dual role of Al₂Ca precipitates in promoting recrystallization through PSN while simultaneously restricting excessive grain growth through Zener pinning. Full article

The hot deformation behavior of a Mg-9.2Er-4.9Sm-2.2Zn-0.6Zr (wt.%) alloy, with emphasis on the role of grain size and long-period stacking-ordered (LPSO) phases, was examined via comparison experiments. Two types of samples were obtained through distinct heat treatment schedules: sample A had a smaller grain size, featuring block-shaped LPSO phases at grain boundaries and lamellar LPSO phases within grains, while sample B had a larger grain size and few LPSO phases. The hot deformation behavior was characterized by the true stress–strain curve within the processing window of 300–450 °C and 0.001–1 s⁻¹. The block-shaped LPSO phases contributed more significantly to strain hardening, leading to elevated flow stress in sample A, particularly under low-temperature and high-strain-rate conditions. Through the particle-stimulated nucleation (PSN) mechanism, block-shaped LPSO phases demonstrated greater efficiency in promoting Dynamic recrystallization (DRX) compared to lamellar LPSO phases; additionally, the synergistic effect between LPSO phases and grain boundary density further improved DRX efficiency. During hot deformation, dynamic precipitation of both block-shaped and lamellar LPSO phases occurred. The formation of block-shaped phases required a longer duration than that of lamellar ones. The presence of the LPSO kink exerted an influence on DRX, while a significant angle kink can promote DRX. Full article

Microstructural analysis of hot-compressed magnesium alloys is crucial for understanding the plastic formability of magnesium alloys during thermo-mechanical processing. Thermal compression tests and finite element simulations were conducted on a low rare-earth (RE) Mg-1.8Nd-0.4Zr-0.3Ca alloy. Multiple microstructural characterization techniques were employed to analyze slip systems, twinning mechanisms, dynamic recrystallization (DRX), and precipitate phases in the hot-compressed alloy. The results demonstrated that the equivalent strain distribution within compressed specimens exhibits heterogeneity, with a larger equivalent strain in the core. After thermal compression, the original microscopic structure formed a necklace-like structure. The primary DRX mechanisms comprise continuous dynamic recrystallization (CDRX), twin-induced dynamic recrystallization (TDRX), and particle-stimulated nucleation (PSN). Pyramidal slip and recrystallization constitute primary contributors to peak texture weakening and tilting. Mg₄₁Nd₅ and α-Zr phases enhanced dislocation density by impeding dislocation motion and promoting cross-slip activation. Hot compression provided the necessary thermal activation energy and stress conditions for solute atom diffusion and clustering, triggering dynamic precipitation of Mg₄₁Nd₅ phases. Full article

Magnesium and its rare-earth alloys are extensively studied for their lightweight properties and high specific strength, making them attractive for aerospace, automotive, and biomedical applications. However, their hexagonal close-packed structure leads to a strong basal texture, limiting plasticity and formability at room temperature. Considerable research has been devoted to texture control strategies, including alloying, thermomechanical processing, and recrystallization mechanisms, yet a comprehensive understanding of their effects remains an ongoing research focus. This review summarizes recent advances in texture regulation of rare-earth magnesium alloys, focusing on the role of RE elements (Gd, Y, Nd, Ce) and non-RE elements (Zn, Ca) in modifying basal texture and enhancing mechanical properties. The influence of key processing techniques, such as extrusion, rolling, equal channel angular pressing, and rotary shear extrusion, is discussed in relation to their effects on recrystallization behavior. Additionally, the mechanisms governing texture evolution, including continuous dynamic recrystallization, discontinuous dynamic recrystallization (DDRX), and particle-stimulated nucleation, are critically examined. By integrating recent findings, this review provides a systematic perspective on alloying strategies, processing conditions, and recrystallization pathways, offering valuable insights for the development of high-performance magnesium alloys with improved formability and mechanical properties. Full article

A simple short-flow thermo-mechanical treatment (TMT) named L-ITMT (consisting of three steps: solution, warm deformation, and solution) was applied to ultra-high-strength Al-10.0Zn-2.7Mg-2.3Cu alloy to study the influence of the deformation degree on the particle distribution, resolubility, microstructure evolution, recrystallization mechanism, formation and development of deformation bonds, and mechanical properties. Increasing the rolling deformation during the L-ITMT process can effectively break up the second phase at the grain boundary and promote its dissolution, which is beneficial to aging precipitation strengthening and improves the strength of the alloy. The dominant mechanism changes from recovery to recrystallization when the deformation degree reaches 80%. As the strain increases, the deformation band becomes flatter and eventually becomes nearly parallel to the RD direction, promoting the occurrence of geometric recrystallization or continuous recrystallization (CRX). Under high-strain conditions, the formation mechanisms of recrystallized grains include discontinuous recrystallization (DRX), CRX, and particle-stimulated nucleation (PSN), but the main contributions to the formation of large-area fine-grained bands are CRX and PSN. The results showed that as the deformation degree increased from 10% to 80%, the improvement of solid solubility and grain refinement in the short-flow TMT process increased the ultimate tensile strength (701 MPa), yield strength (658 MPa), and elongation (11.3%) of the alloy by 15.7%, 10.8%, and 842%, respectively. This shows that the short L-ITMT process has a synergistic effect in significantly improving the plasticity and maintaining the strength of this ultra-high strength Al-Zn-Mg-Cu alloy. Full article

The effect of an erbium alloying on the hot deformation behavior of the crossover Al3Zn3Mg3Cu0.2Zr alloy was investigated in detail. First of all, Er increases the solidus temperature of the alloy. This allows hot deformation at a higher temperature. The precipitates resulting from the Er alloying of the Al3Zn3Mg3Cu0.2Zr alloy were analyzed using transmission electron microscopy. Erbium addition to the alloy produces the formation of more stable and fine L1₂-(Al₃(Zr, Er)) precipitates with a size of 20–60 nm. True stress tends to increase with a decline in the temperature and an increase in the deformation rate. The addition of Er leads to decreases in true stress at the strain rates of 0.01–1 s⁻¹ due to particle-stimulated nucleation softening mechanisms. The effective activation energy of the alloy with the Er addition has a lower value, enabling an easier hot deformation process in the alloy with an elevated volume fraction of the intermetallic particles. The addition of Er increases the strain rate sensitivity, which makes the failure during deformation less probable. The investigated alloys have a significant difference in the dependence of the activation volume on the temperature. The flow instability criterion allows better deformability of Er-doped alloys and enables the alloys to be formed more easily. The evenly distributed particles prevent the formation of shear bands with elevated storage energy and decrease the probability of crack initiation during the initial stages of hot deformation when only one softening mechanism (dynamic recovery) is working. The microstructure analysis proves that dynamic recovery is the main softening mechanism. Full article

Magnesium alloys with a high volume fraction of secondary phases exhibit inferior formability. Therefore, investigating their thermal deformation characteristics is critical for optimizing thermal processing techniques. In this work, isothermal compression experiments were performed on a Mg-15Gd-8Y-6Al-0.3Mn alloy with an elastic modulus of 51.3 GPa with a substantial volume of aluminum-rare earth (Al₂RE) phases. The rheological behavior and microstructural evolution of the material were systematically investigated at varying temperatures (350–500 °C) and strain rates (0.001–1.000 s⁻¹). The calculated thermal processing diagram indicates that the unstable region gradually enlarges with increased strain, and all unstable regions appear within the high-strain-rate, low-temperature domain. The ideal thermal processing range of the alloy is 350–500 °C at strain rates ranging from 0.001 to 0.016 s⁻¹. Particle-stimulated nucleation and discontinuous dynamic recrystallization are both verified to be responsible for the recrystallized microstructure of the alloy. The recrystallized grains exhibit a relatively random crystallographic orientation. As recrystallization proceeds, the texture gradually transitions from a typical [0001] texture in the compression direction to a random texture accompanied by decreased texture intensity. This work sheds new light on the thermo-mechanical processing of high-modulus Mg alloys, which could help design suitable processing techniques for related materials. Full article

This study investigated the microstructure, mechanical properties, and nucleation mechanism of acicular ferrite (AF) present in hot-rolled Ti deoxidized steel. In our experiments, the impact toughness of Ti deoxidized steel is significantly increased to 144 J at −20 °C, while those Mn and Al deoxidized steels are only 9 J and 18 J, respectively. Interlocked AF is the primary microstructure of Ti deoxidized steel. The second-phase particles of the core–shell-type structure, in which Ti₂O₃ is the nucleus and TiO is the outermost shell, act as effective nucleating agents to stimulate AF nucleation. The low lattice disregistry between TiO and AF is the main factor contributing to the production of AF. It is also revealed that Ti₂O₃ and MnS fulfill the particular orientation relationship, contributing to the formation of an Mn-depleted zone (MDZ) adjacent to MnS, proposed to be one of the possible mechanisms for promoting AF nucleation. Full article

This study explores the effects of Zn addition through micro-alloying on the microstructure and discharge performance of Mg-Al-Mn-Ca alloy anodes for magnesium-air batteries. The results show that the second-phase particles (d > 1 μm) in a Mg-Al-Mn-Ca alloy promote dynamic recrystallization (DRX) via particle-stimulated nucleation (PSN), resulting in a uniform equiaxed grain structure and fiber texture. In contrast, Zn and Ca co-segregation in a Mg-Al-Mn-Ca-Zn alloy facilitates continuous dynamic recrystallization (CDRX) and, combined with the PSN mechanism, forms a unique structure where three types of grains with different grain boundary densities coexist. The addition of Zn and Ca effectively reduces the c/a axis ratio, promoting texture homogenization. The Mg-Al-Mn-Ca alloy exhibits rough discharge surfaces due to simultaneous discharge at numerous grain boundaries and severe hydrogen evolution corrosion from micro-galvanic effects, inducing the chunk effect (CE). Conversely, the structure where three types of grains with different grain boundary densities coexist in the Mg-Al-Mn-Ca-Zn alloy promotes discharge product detachment through stress cracking, achieving uniform discharge and significantly enhancing discharge performance. The uniform texture reduces hydrogen evolution corrosion, improving anode utilization. This study demonstrates that controlling the microstructure, particularly grain boundary density and grain texture, enables the development of high-performance Mg-Al-Mn-Ca-Zn alloy anodes, especially at higher current densities, offering a new strategy for designing efficient magnesium alloy anode materials. Full article

For this article, hot compression tests were carried out on homogenized 2050 Al-Cu-Li alloys under different deformation temperatures and strain rates, and an Arrhenius-type constitutive model with strain compensation was established to accurately describe the alloy flow behavior. Furthermore, thermal processing maps were created and the deformation mechanisms in different working regions were revealed by microstructural characterization. The results showed that most of the deformed grains orientated toward <101>//CD (CD: compression direction) during the hot compression process, and, together with some dynamic recovery (DRV), dynamic recrystallization (DRX) occurred. The appearance of large-scale DRX grains at low temperatures rather than in high-temperature conditions is related to the particle-stimulated nucleation mechanism, due to the dynamic precipitation that occurs during the deformation process. The hot-working diagrams with a true strain of 0.8 indicated that the high strain-rate regions C (300 °C–400 °C, 0.1–1 s⁻¹) and D (440 °C–500 °C, 0.1–1 s⁻¹) are unfavorable for the processing of 2050 Al-Li alloys, owing to the flow instability caused by local deformation banding, microcracks, and micro-voids. The optimum processing region was considered to be 430 °C–500 °C and 0.1 s⁻¹–0.001 s⁻¹, with a dissipation efficiency of more than 30%, dominated by DRV and DRX; the DRX mechanisms are DDRX and CDRX. Full article

Grain boundary engineering (GBE) was carried out on a nickel-based alloy (GH3535, Ni-16Mo-7Cr-4Fe), which intrinsically has many strings of primary molybdenum carbides. The strings induce inhomogeneous grain size distributions and increase the difficulties in achieving a GBE microstructure. In this work, the effects of the primary carbide distribution on the grain boundary network (GBN) evolution were investigated. A higher proportion of Σ3ⁿ grain boundaries (GBs) associated with extensive multiple twinning events was achieved in the specimen with more dispersive and finer primary carbides, which are the results of cross-rolling, i.e., cold rolling with a changed direction. In a starting microstructure with many strings of primary carbides, the dense and frequent occurrence of particle-stimulated nucleation (PSN) around the carbides induced more general high-angle GBs into the GBN, and the inhibition of GB migrations by the carbide strings suppressed the formation of large-sized highly twinned grain clusters. As a consequence, the Σ3ⁿ GBs could not be effectively enhanced. Full article

The Al–Mn alloy heat exchanger fin production process includes a brazing treatment at s high temperature of 600 °C, in which coarse grains are preferred for their high resistance to deformation at elevated temperatures by decreasing the grain boundary sliding. In this study, Al-1.57Mn-1.57Zn-0.58Si-0.17Fe alloy foils cold rolled by 81.7% (1.1 mm in thickness) and 96.5% (0.21 mm in thickness) were annealed at 100–550 °C for 1 h to investigate their recrystallization behavior, grain sizes, and precipitates by increasing the annealing temperature, using micro-hardness measurement, electron back-scattered diffraction (EBSD), scanning electron microscopy (SEM), and transmission electron microscopy (TEM) techniques. The micro-hardness results showed that the recrystallization finishing temperatures for the two samples were almost the same, 323 ± 2 °C. The EBSD results showed that when the annealing temperature decreased from 550 to 400 °C, the recrystallized grain sizes of the two samples were nearly identical—both increased slightly. Further decreasing the annealing temperature from 400 to 330 °C caused the grain sizes to increase more, with the thinner foil sample having a more significant increase. The SEM and TEM observations showed that the micron-sized primary-phase remained unchanged during the annealing process. The nano-sized secondary phase precipitates formed during the hot-rolling process experienced a coarsening and dissolving process upon annealing. The particle size of the secondary phase increased from 32 nm to 44 nm and the area fraction decreased from 4.2% to 3.8%. The nucleation analysis confirmed that the large primary-phase could act as a nucleation site through particle stimulated nucleation (PSN) mode. The relatively dense secondary phase precipitates with small sizes at lower temperatures could provide higher Zener drag to the grain boundaries, leading to fewer nuclei and thereafter coarser grains. The coarsening of the recrystallized grains in the foils could be implemented through thickness reduction and/or precipitation processes to form densely distributed nano-sized precipitates. Full article

In this paper, the electron backscatter diffraction (EBSD) technique was used to analyze the dynamic recrystallization (DRX), twinning, slip behavior, and texture evolution during forging and subsequent extruding deformation. The results show that, as the degree of strain increased (forging to extruding), the degree of DRX increased, and the DRX mechanism changed from discontinuous DRX (DDRX) during forging to DDRX and continuous DRX (CDRX) during extruding. Particle stimulation nucleation (PSN) promoting DRX occurred during deformation. The deformation process mainly produced {10–12} twins (TTW) and played a role in coordinating the deformation. The slip behavior also changed according to an analysis of in-grain misorientation axes (IGMA) results, changing from slip-dominated with a basal <a> slip to co-dominated with multiple slip modes, with the activation of mainly prismatic <a> and pyramidal <c+a> slip. Meanwhile, the strong basal texture at the beginning of the deformation also changed, and the texture strength decreased from 24.81 to 15.56. The weakening of the texture was mainly due to the formation of DRX grains and twins, as the newly formed DRX and twins reoriented. In the later stages of deformation, the activation of prismatic <a> slip and pyramidal <c+a> slip changed the basal texture component. Based on microstructural analysis, the improvement in mechanical properties was due to fine-grain strengthening and load-transfer strengthening. The ultimate tensile strength (UTS) was 370.5 MPa, the yield strength (YS) was 340.1 MPa, and the elongation (EL) was 15.6%. Full article

In this work, Inconel 625 alloy is explored regarding high-temperature tensile deformation and fracture behaviors at a strain rate of 0.005–0.01 s⁻¹ under a deformation temperature ranging from 700–800 °C. The subsequent analysis focuses on the impact of deformation parameters on flow and fracture characteristics. The fractured surface reveals that ductile fracture is dominated by the nucleation, growth, and coalescence of microvoids as the primary failure mechanisms. The elevated deformation temperature and reduced strain rate stimulate the level of dynamically recrystallized (DRX) structures, resulting in intergranular fractures. The Arrhenius model and the particle swarm optimization-artificial neural network (PSO-ANN) model are developed to predict the hot tensile behavior of the superalloy. It indicates that the PSO-ANN model exhibits a correlation coefficient (R) as high as 0.9967, surpassing the corresponding coefficient of 0.9344 for the Arrhenius model. Furthermore, the relative absolute error of 9.13% (Arrhenius) and 1.85% (PSO-ANN model) are recorded. The developed PSO-ANN model accurately characterizes the flow features of the Inconel 625 superalloy with high precision and reliability. Full article