Search Results (156)

Understanding the limitations of cold-formed aluminum alloys in practice applications is essential, particularly due to the risk of substructural changes and a reduction in strength when exposed to elevated temperatures. In this study, the thermal stability of the ultra-fine-grained (UFG) structure formed by equal channel angular pressing (ECAP) at room temperature and the mechanical properties of the AlSi7MgCu0.5 alloy were investigated. Prior to ECAP, the plasticity of the as-cast alloy was enhanced by a heat treatment consisting of solution annealing, quenching, and artificial aging to achieve an overaged state. Four repetitive passes via ECAP route A resulted in the homogenization of eutectic Si particles within the α-solid solution, the formation of ultra-fine grains and/or subgrains with high dislocation density, and a significant improvement in alloy strength due to strain hardening. The main objective of this work was to assess the microstructural and mechanical stability of the alloy after post-ECAP annealing in the temperature range of 373–573 K. The UFG microstructure was found to be thermally stable up to 523 K, above which notable grain and/or subgrain coarsening occurred as a result of discontinuous recrystallization of the solid solution. Mechanical properties remained stable up to 423 K; above this temperature, a considerable decrease in strength and a simultaneous increase in ductility were observed. Synchrotron radiation X-ray diffraction (XRD) was employed to analyze the phase composition and crystallographic characteristics, while transmission electron microscopy (TEM) was used to investigate substructural evolution. Mechanical properties were evaluated through tensile testing, impact toughness testing, and hardness measurements. Full article

In this study, we have explored the thermomechanical processing on 0.1C3Mn steel to produce an ultrafine-grained (UFG) dual-phase (DP) microstructure. The composition was designed to allow a decrease in temperature for the warm deformation of austenite. It was found that the warm deformation of austenite induced a dramatic ferrite transformation, in contrast to the absence of the formation of ferrite in the well-annealed state. Compression by 60% at 650 °C resulted in the generation of a UFG-DP microstructure with a ferrite grain size of 1.4 μm and a ferrite volume fraction of 62%. The UFG-DP 0.1C3Mn steel presents a good combination of strength, ductility and fracture resistance, and the fracture strain of the UFG-DP is higher than the as-quenched low-carbon martensite. The high fracture strain of the UFG-DP could be attributed to delayed void nucleation and constrained void growth, as revealed by the quantitative X-ray tomography. Full article

Thermomechanical processing by applying deformation-induced ferrite transformation (DIFT) is an effective method of producing ultrafine-grained (UFG) ferritic steels, which usually present high yield strength but low strain hardening. In this study, we explored the concept of DIFT in the processing of UFG dual-phase (DP) steel, in order to improve its strain hardening capability and thus its ductility. The processing temperature was reduced to enhance the dislocation storage in austenite. It was found that the warm deformation of austenite induced a dramatic occurrence of DIFT, resulting in the formation of UFG-DP microstructures along the whole thickness of the specimen. In the UFG-DP microstructure, the average ferrite grain size was 1.2 μm and the ferrite volume fraction was 44 vol.%. The observation of twinned martensite suggests the occurrence of carbon partitioning during the DIFT process. The UFG-DP microstructure exhibited a good combination of strength and ductility, which was enabled by the synergy of the ultrafine ferrite grains and the efficient composite effect. The outcome of this study provides a novel pathway to develop advanced hot-rolled steels with a UFG-DP microstructure and which are associated with the advantages of their readiness to be scaled up and low costs. Full article

The aim of this study was the synthesis of intermetallic crystal dispersion in an ultra-fine-grained (UFG) aluminum matrix by the equal-channel angular pressing (ECAP) process, which provides severe plastic deformation (SPD) of aluminum-5 and 10% wt. nickel powders. The ECAP process of up to 20 passes was carried out at 200 °C. Intermetallic crystal particles in the UFG Al matrix were obtained in sintered samples at 500 °C for 1 and 5 h, interrupting the ECAP process. The scanning electron microscope (SEM) images were received for the microstructural evaluations. According to the SEM images, it was understood according to the quantitative observation and energy dispersive spectroscopy (EDS) analysis results that the Ni powders added to Al mostly remained in the block state in the matrix structure after the ECAP processes but started to dissolve in the matrix by increasing the ECAP pass number and sintering temperature. DSC and XRD analyses were carried out to investigate intermetallic crystal evaluation in the material. According to DSC analyses, the melting degrees of the alloys increase with the amount of Ni added. Melting enthalpies and melting degrees showed small changes in the number of ECAP passes. Also, electron backscatter diffraction (EBSD) images were obtained for the samples’ grain size and grain boundary angle measurements. It has been understood that the number of passes and the process temperature are effective parameters for the solid-state synthesis of Al₃Ni intermetallic crystals in UFG by the ECAP process. Full article

Aluminum matrix composites (AMCs) with hetero-grains exhibit high strength with good ductility. A trimodal grain structure composed of ultrafine grains (UFGs), fine grains (FGs) and coarse grains (CGs) prevents the pre-mature cracking of hetero-zone boundaries in conventional bimodal grain structures; thus, it is favored by AMCs. However, the design of the size and distribution of hetero-domains in trimodal AMCs is tough, with complicated multi-scale deformation mechanisms. This study tunes the distribution of FG domains elaborately via altering the volume fraction of FG from 10 vol.% to 60 vol.% and investigates the distribution effect of FG domains on strength–ductility synergy. The optimized 2024 Al matrix composites with 30 vol.% FG exhibited a tensile strength of over 700 MPa and an elongation of 7.5%, respectively, realizing a good combination of high strength and ductility. This work enlightens the heterostructure design with a balance between heterogeneous deformation induced (HDI) strain hardening and high-content soft phase induced strain homogenization. Full article

The last two decades have witnessed significant progress in the development of severe plastic deformation techniques to produce ultrafine-grained materials with new and superior properties. This review examines works and achievements related to the low-temperature superplasticity of ultrafine-grained aluminum alloys. The examples are provided of the possibility to observe low-temperature superplasticity in aluminum alloys at temperatures less than 0.5 T_melt and even at room temperature, and herein, we demonstrate the cases of achieving high ductility and high strength in aluminum alloys from processing utilizing severe plastic deformation. Special emphasis is placed on recent studies of the formation of segregations of alloying elements at grain boundaries in UFG Al alloys and their influence on the development of grain boundary sliding and manifestation of low-temperature superplasticity. In addition, the current status and innovative potential of low-temperature superplasticity in aluminum alloys are observed. Full article

In order to gain insight into the influence of grain size on precipitation thermodynamics, bulk materials of coarse-grained (CG), ultrafine-grained (UFG) (with or without dislocations), and nanocrystalline (NC) 7075 Al alloy have been fabricated by solid solution treatment, equal-channel angular pressing (ECAP), or high-pressure torsion (HPT) processes. The precipitation behavior and the corresponding thermal phenomenon were studied by transmission electron microscopy (TEM) and differential scanning calorimetry (DSC) heating. The results indicated that there are significant differences in precipitation thermodynamics among the four bulk materials. In the CG and UFG materials without dislocations, homogeneous nucleation is the primary precipitation mechanism. However, the nucleation of the GP zones is suppressed at lower temperatures due to a reduction in the number of residual vacancies and the supersaturation in the UFG interiors. This is attributed to the absorption of vacancies and solute atoms by a greater volume of grain boundaries. It can be observed that the greater the excess of vacancies remaining in grain interiors, the lower the temperature at which nucleation of GP zones occurs. Defect-assisted heterogeneous nucleation was identified as the predominant precipitation mechanism in the UFG materials with dislocations and the NC materials. These defects encompass dislocations, lattice distortions, and grain boundaries. The decomposition processes of solid solutions were found to be almost complete at a lower temperature. The presence of dislocations, lattice distortions, and grain boundaries enables solute atoms to diffuse at a much faster rate, significantly enhancing the precipitation rate and reducing the nucleation and formation energies of various precipitate phases. Full article

Strain-controlled low cycle fatigue (LCF) tests were conducted on conventionally grained (CG) and ultrafine-grained (UFG) Al-Mg-Si alloys treated under various aging conditions. In the cyclic stress response (CSR) curves, CG peak-aged (PA) alloys showed initial cyclic hardening and subsequent saturation, whereas CG over-aged (OA) alloys displayed cyclic softening behavior close to saturation. The UFG materials exhibited continuous cyclic softening except for UFG 3; it originates from the microstructural stability of the UFG materials processed by severe plastic deformation (SPD). Using a strain-based criterion, the LCF behavior and life of the CG and UFG materials were analyzed and evaluated; the results are discussed in terms of strengthening mechanisms and microstructural evolution. In the CG materials, the LCF life changed markedly owing to differences in deformation inhomogeneity depending on the precipitate state. However, the UFG materials displayed a decreasing LCF life as cyclic softening induced by dynamic recovery became more severe; additionally, a relationship between the microstructural stability of the UFG materials and the cyclic strain hardening exponent n′ was suggested. Full article

The mechanical characteristics and sliding friction behaviors of AA7075 samples were studied in regard to structural states formed in them by ECAP and depending on the ECAP pass number. In addition, the effect of a counterbody’s material on the tribological characteristics of the samples was investigated by the examples of AISI 52100 steel, alumina Al₂O₃ and silicon nitride Si₃N₄. Vibration acceleration and acoustic emission signals with parameters such as acoustic emission energy and median frequency were used for characterizing the sliding regimes. The structural state and mechanical properties of the ECAPed AA7075 samples significantly affected their wear behaviors in dry sliding. The counterbody material had a significant influence on the formation of a transfer layer and the subsurface deformation of samples. The dynamic behavior of the tribosystem was studied and the relationship between the sliding parameters, vibrometry and acoustic emission signals was established. Full article

Medium manganese (medium-Mn) steel, one of the third-generation advanced high-strength steels (AHSS), delivers impressive mechanical properties such as high yield strength, ultimate tensile strength, and uniform elongation. One notable feature of medium-Mn steels is the presence of ultrafine-grained (UFG) austenite, achieved through phase transformation from the parent martensite phase during intercritical annealing. While, in general, UFG is considered a strengthening mechanism, the impact of UFG austenites in medium-Mn steel has not been fully studied. In this manuscript, we advance our previous work on crystal plasticity simulation based on the Taylor model to consider fully resolved high-fidelity microstructures and systematically study the influence of the UFG austenites. The original microstructure with UFG is reconstructed from a set of serial electron backscatter diffraction (EBSD) scans, where the exact grain morphology, orientation, and phase composition are preserved. This microstructure was further analyzed to identify the UFG austenites and recover them to their parent martensite before the intercritical annealing. These two high-fidelity microstructures are used for a comparative study using dislocation density-based crystal plasticity finite modeling to understand the impact of UFG austenites on both the local and overall mechanical responses. Full article

The mechanical characteristics of polycrystalline metallic materials are influenced significantly by various microstructural parameters, one of which is the grain size. Specifically, the strength and the toughness of polycrystalline metals exhibit enhancement as the grain size is reduced. Applying severe plastic deformations (SPDs) has a noticeable result in obtaining metallic materials with ultrafine-grained (UFG) microstructure. SPD, executed through conventional shaping methods like extrusion, plays a pivotal role in the evolution of the texture, which is closely related to the plastic behavior and ductility. A number of SPD processes have been developed to generate ultrafine-grained materials, each having a different shear deformation mechanism. Among these methods, linear twist extrusion (LTE) presents a non-uniform and non-monotonic form of severe plastic deformation, leading to significant shifts in the microstructure. Prior research demonstrates the capability of the LTE process to yield consistent, weak textures in pre-textured copper. However, limitations in production efficiency and the uneven distribution of grain refinement have curbed the widespread use of LTE in industrial settings. This has facilitated the development of an improved novel method, that surpasses the traditional approach, known as the nonlinear twist extrusion procedure (NLTE). The NLTE method innovatively adjusts the channel design of the mold within the twist section to mitigate strain reversal and the rotational movement of the workpiece, both of which have been identified as shortcomings of twist extrusion. Accurate anticipation of texture changes in SPD processes is essential for mold design and process parameter optimization. The performance of the proposed extrusion technique should still be studied. In this context, here, a single crystal (SC) of copper in billet form, passing through both LTE and NLTE, is analyzed, employing a rate-dependent crystal plasticity finite element (CPFE) framework. CPFE simulations were performed for both LTE and NLTE of SC copper specimens having <100> or <111> directions parallel to the extrusion direction initially. The texture evolution as well as the cross-sectional distribution of the stress and strain is studied in detail, and the performance of both processes is compared. Full article

The mechanical properties of various Ti-6Al-4V alloys are influenced by their respective microstructures. This study generated an ultrafine-grain (UFG) Ti-6Al-4V alloy featuring bimodal grain distribution characteristics achieved through initial heat treatment, multi-axial forging (MF), and annealing. The study also extensively examined the evolution process of the alloy’s microstructure. By subjecting the materials to heat treatments at 900 °C with air cooling and 950 °C with air cooling, both materials were found to be consisted of primary α (α_p) and transformed β (α_s+β) regions with different proportions. Following MF, the sample treated at 900 °C displays a microstructure featuring UFGs of α+β surrounding larger micron-sized α_p grains. On the other hand, the sample treated at 950 °C displays a microstructure distinguished by twisted α_s lamellar and fragmented β grains surrounding larger micron-sized α_p grains. Following annealing, no significant grain growth was observed in the sample. The geometrically necessary dislocations (GNDs) within the UFGs were eliminated, though some GNDs persisted within the α_p grains. The samples undergoing the 900 °C heat treatment, MF, and subsequent annealing exhibited elevated strength (1280 MPa) and total elongation (10.7%). This investigation introduces a novel method for designing the microstructure of the Ti-6Al-4V alloy to achieve superior performance. Full article

A homogenized, supersaturated AlZnMgZr alloy was processed via severe plastic deformation (SPD) using a high-pressure torsion (HPT) technique for different revolutions at room temperature to obtain an ultrafine-grained (UFG) microstructure. The microstructure and mechanical properties of the UFG samples were then studied using transmission electron microscopy (TEM), differential scanning calorimetry (DSC), and tensile and hardness measurements. The main purpose was to study the effect of shear strain on the evolution of the microstructure of the investigated alloy. We found a very interesting evolution of the decomposed microstructure in a wide range of shear strains imposed by HPT. While the global properties, such as the average grain size (~200 nm) and hardness (~2200 MPa) appeared unchanged, the local microstructure was continuously transformed. After 1 turn of HPT, the decomposed UFG structure contained relatively large precipitates inside grains. In the sample processed by five turns in HPT, the segregation of Zn atoms into grain boundaries (GBs) was also observed. After 10 turns, more Zn atoms were segregated into GBs and only smaller-sized precipitates were observed inside grains. The intensive solute segregations into GBs may significantly affect the ductility of the material, leading to its ultralow-temperature superplasticity. Our findings pave the way for achieving advanced microstructural and mechanical properties in nanostructured metals and alloys by engineering their precipitation and segregation by means of applying different HPT regimes. Full article

A theoretical model is suggested that describes the effect of deformation temperature on the yield stress of an ultrafine-grained (UFG) Al-Cu-Zr alloy structured with severe plastic deformation. Within the model, nanoprecipitates (NPs) of Al₂Cu act as sources of lattice dislocations in the presence of a number of extrinsic grain-boundary dislocations (EGBDs) near the NPs. It is shown that the number of EGBDs near the NPs decreases with a drop in the deformation temperature that increases the yield stress of the Al-Cu-Zr alloy. The proposed model is in good quantitative agreement with available experimental results. Full article

The potential medical Zn-1.7%Mg and Zn-1.7%Mg-0.2%Zr alloys strengthened using high-pressure torsion (HPT) were investigated in this work. HPT led to a significant refinement of the microstructure of both alloys with the formation of an ultrafine-grained structure (UFG). The average grain size after HPT was ~700–800 nm for both alloys. The formation of the UFG structure led to an increase in the ultimate tensile strength of up to 401 ± 16 and 482 ± 12 MPa for the Zn-1.7%Mg and Zn-1.7%Mg-0.2%Zr alloys, respectively. Additionally, a variation in ductility of the Zn-1.7%Mg and Zn-1.7%Mg-0.2%Zr alloys of up to 56.3 ± 16.9% and 4.4 ± 0.6%, respectively, was also observed, apparently due to textural changes. HPT led to a small increase in the degradation rate of the alloys after 1 day of incubation in the medium. However, an increase in the incubation period of up to 30 days slowed down the degradation process and leveled the difference between the initial and HPT-treated state of the alloys. HPT did not affect the cytotoxicity of the Zn-1.7%Mg-0.2%Zr alloy and contributed to the reduction of hemolysis. Thus, the processing of the Zn-1.7%Mg and Zn-1.7%Mg-0.2%Zr alloys using HPT accelerated their biodegradation without compromising their biocompatibility. Full article