A new approach of the constrained groove pressing process on Al5083-O alloy using PMMA polymer, without die non-friction coefficient: nanostructure, mechanical Properties and hardness

The Constrained Groove Pressing (CGP) on annealed Al5083 (Al5083-O) alloy sheets by means of Polymethyl Methacrylate (PMMA) polymer is investigated in this research. Input parameters include Traverse Speed (1, 2, and 3 mm/min), Pass Number (1, 2, 3, and 4), and Lubricants (Grease, Oil, and without lubricants). Reciprocally, output parameters consist of Nanostructure (SEM and EBSD images), Hardness (HV), and Mechanical Properties – Impact Strength (kJ/m2), Tensile Strength (MPa), Young's Modulus (MPa), and Elongation (%). Revealed by the results, the impact strength is gradually improved in the 1st, 2nd, 3rd, and 4th passes by respectively adding oil and grease, compared to the state of using no lubricant. The impact strength results demonstrated that the addition of grease has a significant effect on the impact strength of composite samples. In order to build a high-quality product through the CGP process, it is very important for the mechanical properties to be based on the input parameters. In CGP processes, the Continuous Dynamic Recrystallization (CDRX) is considered as the ultrafine-grained mechanism. To predict the grain size evolution and the plastic deformation rate, the combination of Finite Element (FE) method and the ETMB model is utilized. Indicating the high generalizability and reliability as compared to other modeling methods, both the experimental test results and the ETMB model data, which have a higher degree of accuracy, are presented.

Numerical Modeling of Continuous Dynamic Recrystallization in Sn-Based Solder Connection Under Cyclic Loading

The reoccurring cyclic load imposed onto soldered electronic components during their operation time leads to accumulation of inelastic strains in the structure. On a microscale level, the degree of plastic deformation is determined by the formation and annihilation of dislocations, leading to continuous refinement by creation of new grain boundaries, precipitates relocation and growth. This microstructure rearrangement, triggered by an increasing amount of inelastic deformation, is defined as dynamic recrystallization. This work presents a macroscale modelling approach for the description of continuous dynamic recrystallization observed in Sn-based solder connections. The model used in this work describes kinetics of macroscopic gradual evolution of equivalent grain size, where the initial grain size is continuously refined with increasing accumulated inelastic strain until a saturation grain size is reached. The rate and distribution of dynamic recrystallization is further numerically modelled dependent on the effective accumulated inelastic strain and governing stress multiaxiality. A parameter study of the presented model and its employment in finite element (FE) simulation is further described. Finally, FE simulation of the grain size evolution is demonstrated on an example of a bulky sample under isothermal cyclic mechanical loading, as well as a BGA-like structure under tensile, shear and mixed mode cyclic load.

Deformation Behavior and Properties of 7075 Aluminum Alloy under Electromagnetic Hot Forming

High-strength 7075 aluminum alloy is widely used in the aerospace industry. The forming performance of 7075 aluminum alloy is poor at room temperature. Therefore, hot forming is mainly adopted. Electromagnetic forming is a high-speed forming technology that can significantly improve the forming limit of difficult-to-deform materials. However, there are few studies on electromagnetic hot forming of 7075-T6 aluminum alloy. In this study, the deformation behavior of 7075-T6 aluminum alloy in the temperature range of 25 °C to 400 °C was investigated. As the temperature increased, the sheet forming height first decreased, then increased. When the forming temperature is between 200 °C and 300 °C, η phase coarsening leads to a decrease in stress and hardness of the material. When the forming temperature is between 300 °C and 400 °C, continuous dynamic recrystallization of 7075 aluminum alloy occurs, resulting in grain refinement and an increase in stress and hardness. The results of numerical simulations and experiments all show that the forming height and deformation uniformity of the sheet metal are optimal at 400 °C, compared to 200 °C.

Deformation and Phase Transformation of Disordered α Phase in the (α + γ) Two-Phase Region of a High-Nb TiAl Alloy

In this paper, the deformation and phase transformation of disordered α phase in the (α + γ) two-phase region in as-forged Ti-44Al-8Nb-(W, B, Y) alloy were investigated by hot-compression and hot-packed rolling. The detailed microstructural evolution demonstrated that the deformed microstructure was significantly affected by the deformation conditions, and the microstructure differences were mainly due to the use of a lower temperature and strain rate. Finer α grains were formed by the continuous dynamic recrystallization of α lamellae and α grains distributed around lamellar colonies. Moreover, the grooved γ grains formed by the phase transformation from α lamellae during hot rolling cooperated with and decomposed α lamellae. A microstructure evolution model was built for the TiAl alloy at 1250 °C during hot rolling.

Investigation into Microstructure Evolution of Co–Ni–Cr–W–Based Superalloy During Hot Deformation

Hot compression tests were conducted using a Gleeble 3500 thermomechanical simulator at temperatures ranging from 1,000 to 1,200°C with the strain rate ranging from 0.1 to 10 s−1. Electron backscatter diffraction (EBSD) technique was employed by investigating the microstructure evolution during hot deformation. Microstructure observations reveal that deformation temperatures and strain rates have a significant effect on the DRX process. It is found that the fraction and grain size of DRX increase with the decreasing deformation temperature, along with the increasing high-angle grain boundaries (HAGBs). The fraction of DRX first decreases and then increases with the increase of strain rates. It is noted that there are both the nucleation mechanisms of discontinuous dynamic recrystallization (DDRX) and continuous dynamic recrystallization (CDRX) during the DRX process for Co–Ni–Cr–W–based superalloys. DDRX and CDRX are the primary and subsidiary nucleation mechanisms of DRX, respectively. It is also found that deformation temperatures and strain rates have almost no effect on the primary and subsidiary nucleation mechanisms of DRX. At the temperature above 1,150°C, the complete DRX occurred with the average grain sizes of about 25.32–29.01 μm. The homogeneity and refinement of microstructure can be obtained by selecting the suitable hot deformation parameters.

A Comparative Study on the Hot Deformation Behavior of As-Cast and Twin-Roll Cast Mg-6.8Y-2.5Zn-0.4Zr Alloy

The Mg-6.8Y-2.5Zn-0.4Zr (WZ73) alloy exhibits different microstructure characteristic after conventional casting compared to the twin-roll cast (TRC) state. Twin-roll casting results in a finer microstructure, where the LPSO phases are more finely distributed and less strongly connected. A transfer of the hot deformation behavior from the as-cast condition to the TRC condition is only possible to a limited extent due to the microstructural differences. Both states show differences in the recrystallization behavior during hot deformation. In the conventional cast state, dynamic recrystallization (DRX) is assumed to be delayed by the occurrence of coarse blocky LPSO phases. Main DRX mechanisms are continuous dynamic recrystallization (CDRX), particle stimulated nucleation (PSN) and twin induced dynamic recrystallization (TDRX). The deformed TRC sample showed pronounced DRX at almost all deformation conditions. Besides the TDRX and the PSN mechanism, kink induced dynamic recrystallization (KDRX) can be observed. Optimum deformation conditions for both states are temperatures from 500 °C to 520 °C, and strain rates ranging from 0.01 s−1 to 0.1 s−1 for the as-cast material as well as a strain rate of 1 s−1 for the TRC material.

Microstructural Evolutions of 2N Grade Pure Al and 4N Grade High-Purity Al during Friction Stir Welding

The grain refinement mechanisms along the material flow path in pure and high-purity Al were examined, using the marker insert and tool stop action methods, during the rapid cooling friction stir welding using liquid CO2. In pure Al subjected to a low welding temperature of 0.56Tm (Tm: melting point), the resultant microstructure consisted of a mixture of equiaxed and elongated grains, including the subgrains. Discontinuous dynamic recrystallization (DDRX), continuous dynamic recrystallization (CDRX), and geometric dynamic recrystallization are the potential mechanisms of grain refinement. Increasing the welding temperature and Al purity encouraged dynamic recovery, including dislocation annihilation and rearrangement into subgrains, leading to the acceleration of CDRX and inhibition of DDRX. Both C- and B/-type shear textures were developed in microstructures consisting of equiaxed and elongated grains. In addition, DDRX via high-angle boundary bulging resulted in the development of the 45° rotated cube texture. The B/ shear texture was strengthened for the fine microstructure, where equiaxed recrystallized grains were fully developed through CDRX. In these cases, the texture is closely related to grain structure development.

Dynamic Recrystallization and Its Effect on Superior Plasticity of Cold-Rolled Bioabsorbable Zinc-Copper Alloys

High plasticity of bioabsorbable stents, either cardiac or ureteral, is of great importance in terms of implants’ fabrication and positioning. Zn-Cu constitutes a promising group of materials in terms of feasible deformation since the superplastic effect has been observed in them, yet its origin remains poorly understood. Therefore, it is crucial to inspect the microstructural evolution of processed material to gain an insight into the mechanisms leading to such an extraordinary property. Within the present study, cold-rolled Zn-Cu alloys, i.e., Zn with addition of 1 wt.% and 5 wt.% of Cu, have been extensively investigated using scanning electron microscopy as well as transmission electron microscopy, so as to find out the possible explanation of superior plasticity of the Zn-Cu alloys. It has been stated that the continuous dynamic recrystallization has a tremendous impact on superior plasticity reported for Zn-1Cu alloy processed by rolling to 90% of reduction rate. The effect might be supported by static recrystallization, provoking grain growth and thereby yielding non-homogeneous microstructures. Such heterogeneous microstructure enables better formability since it increases the mean free path for dislocation movement.