Structure Refinement and Fragmentation of Precipitates under Severe Plastic Deformation: A Review

Microstructure and Mechanical Properties of the Joints from Coarse- and Ultrafine-Grained Al-Mg-Si Alloy Obtained via Friction Stir Welding

In the present study, the welding of coarse- (CG) and ultrafine-grained (UFG) Al-Mg-Si alloy using friction stir welding (FSW) was attempted. The purpose of welding the UFG material was to check the possibility of applying FSW to materials with a thermally unstable microstructure, which is achieved by severe plastic deformation. This group of materials has significant potential due to the enhanced mechanical properties as a result of the elevated number of structural defects. The CG sample was also examined in order to assess whether there is an influence of the base material microstructure on the weld microstructure and properties. To refine the microstructure, incremental equal channel angular pressing was used. Plastic deformation resulted in grain refinement from 23 µm to 1.5 µm. It caused an increase in the microhardness from 105 HV0.1 to 125 HV0.1 and the tensile strength from 320 MPa to 394 MPa. Similar welds obtained using an FSW method exhibited good quality and grain size in a stir zone of 5 µm. For both welds, a decrease in the microhardness occurred in the stir zone. However, for the weld of UFG Al-Mg-Si, the microhardness distribution was homogeneous, while for the weld of the CG, it was inhomogeneous, which was caused by different characteristics of the second-phase precipitates. The tensile strength of the welds was lowered and equaled 269 MPa and 220 MPa for the CG and UFG welds, respectively.

Effects of Built Direction and Deformation Temperature on the Grain Refinement of 3D Printed AlSi10Mg Alloy Processed by Equal Channel Angular Pressing (ECAP)

In this work, we used an AlSi10Mg alloy produced by selective laser melting (SLM) to study the effects of build direction and deformation temperature on the grain refinement process. Two different build orientations of 0° and 90° and deformation temperatures of 150 °C and 200 °C were selected to study this effect. Light microscopy, electron backscatter diffraction and transmission electron microscopy were used to investigate the microtexture and microstructural evolution of the laser powder bed fusion (LPBF) billets. Grain boundary maps showed that the proportion of low-angle grain boundaries (LAGBs) dominated in every analysed sample. It was also found that different thermal histories caused by the change in build direction resulted in microstructures with different grain sizes. In addition, EBSD maps revealed heterogeneous microstructures comprising equiaxed fine-grained zones with ≈0.6 μm grain size and coarse-grained zones with ≈10 μm grain size. From the detailed microstructural observations, it was found that the formation of a heterogeneous microstructure is closely related to the increased fraction of melt pool borders. The results presented in this article confirm that the build direction has a significant influence on the microstructure evolution during the ECAP process.

The Effect of Rotary-Die Equal-Channel Angular Pressing Process on the Microstructure, the Mechanical and Friction Properties of GW103 Alloy

In this study, the effect of rotary-die equal-channel angular pressing (RD-ECAP) on the microstructure and texture evolution of GW103 alloy is studied. RD-ECAP processes were carried out for 1, 4 and 12 passes at 450 °C. The mechanical properties and friction behavior of RD-ECAP-processed Mg-10Gd-3Y (wt%) alloy (GW103) are discussed. The results reveal that the size of dynamic recrystallized grains and second-phase particles are significantly refined to about 1.3 μm and 1 μm, respectively. The texture evolution of the processed samples is studied by X-ray diffraction and electron backscattered diffraction techniques. The multiple texture components formed are not observed after the conventional ECAP process. Moreover, different dynamic recrystallization (DRX) mechanisms are systemically analyzed and discussed in view of the texture evolution of ECAP processed samples. The final textures obtained after 12 passes are identified as two types: The C-texture type induced by continuous and discontinuous DRX, and the random texture components induced by reorientation of the initial <101¯0> fiber. Based on the grain refinement, precipitate strengthening and texture weakening mechanisms, a high-performance ternary alloy of Mg-Gd-Y was firstly obtained through 12 passes RD-ECAP processing, with a combination of high yield strength of 312 MPa and a high ductility of 22%. In addition, the friction behaviors are also studied. The multi-pass-processed samples exhibit a relatively lower friction coefficient under a load of 10 N at room temperature.

Perspectives of Microstructure Refinement of Aluminum and Its Alloys by the Reciprocating Extrusion (Cyclic Extrusion Compression—CEC)

This paper presents a study on the perspectives of structure refinement of aluminum and its alloys by reciprocating extrusion (cyclic extrusion compression—CEC). The study included Al99.5 and Al99.992 aluminum and AlMg5 and AlCu4Zr alloy. Aluminum and alloys were deformed by reciprocating extrusion (CEC) in the strain range ϕ = 0.42 (1 CEC cycle) to ϕ = 59.8 (67 CEC cycles). After deformation, the structure of the specimens was investigated by optical microscopy (OM) and transmission electron microscopy (TEM), which revealed that the primary mechanism of hardening, over the range of applied strains, was the result of the propagation of shear bands throughout the specimens. The intersection of shear bands was found to divide the volume of the specimens into nano and microvolumes with dimensions limited by the width of the microbands. Due to structure renewal processes such as polygonization and dynamic geometric recrystallization, the formed micro and nano volumes were transformed into nano and micrograins with large misorientation angles. In terms of the occurrence of grain microstructure, a sustained uniform level of hardening was found, which was defined as steady-state flow. The research has shown that the steady state of flow is a result of the competitive interaction between the processes of hardening and structure renewal. The higher the metal purity, the higher the intensity of the structure renewal processes was. The formation of new grains and their growth under dynamic and post-dynamic recrystallization was observed in Al99.992 aluminum, in which high purity of the metal and high strain accumulation caused the growth of new grains at room temperature.