Ajit R Godbole

Fabrication of ultra-thin nanostructured bimetallic foils by Accumulative Roll Bonding and Asymmetric Rolling

This paper reports a new technique that combines the features of Accumulative Roll Bonding (ARB) and Asymmetric Rolling (AR). This technique has been developed to enable production of ultra-thin bimetallic foils. Initially, 1.5 mm thick AA1050 and AA6061 foils were roll-bonded using ARB at 200°C, with 50% reduction. The resulting 1.5 mm bimetallic foil was subsequently thinned to 0.04 mm through four AR passes at room temperature. The speed ratio between the upper and lower AR rolls was 1:1.3. The tensile strength of the bimetallic foil was seen to increase with reduction in thickness. The ductility of the foil was seen to reduce upon decreasing the foil thickness from 1.5 mm to 0.14 mm, but increase upon further reduction in thickness from 0.14 mm to 0.04 mm. The grain size was about 140 nm for the AA6061 layer and 235 nm for the AA1050 layer, after the third AR pass.

Crack Healing in a Low-Carbon Steel Under Hot Plastic Deformation

The behavior of internal crack healing in low-carbon steel samples undergoing hot plastic deformation was investigated using the MMS 200 thermo-mechanical simulator. The characterization of cracks after plastic deformation was analyzed using scanning electron microscopy under different heating temperatures, reduction ratios, numbers of deformation passes, strain rates, and holding time durations. It was found that the degree of crack healing increases with increasing heating temperature, reduction ratio, and holding time duration, and with decreasing number of deformation passes and strain rate.

A deformation mechanism of hard metal surrounded by soft metal during roll forming

It is interesting to imagine what would happen when a mixture of soft-boiled eggs and stones is deformed together. A foil made of pure Ti is stronger than that made of Cu. When a composite Cu/Ti foil deforms, the harder Ti will penetrate into the softer Cu in the convex shapes according to previously reported results. In this paper, we describe the fabrication of multilayer Cu/Ti foils by the roll bonding technique and report our observations. The experimental results lead us to propose a new deformation mechanism for a hard metal surrounded by a soft metal during rolling of a laminated foil, particularly when the thickness of hard metal foil (Ti, 25 μm) is much less than that of the soft metal foil (Cu, 300 μm). Transmission Electron Microscope (TEM) imaging results show that the hard metal penetrates into the soft metal in the form of concave protrusions. Finite element simulations of the rolling process of a Cu/Ti/Cu composite foil are described. Finally, we focus on an analysis of the deformation mechanism of Ti foils and its effects on grain refinement, and propose a grain refinement mechanism from the inside to the outside of the laminates during rolling.

Tensile fracture of ultrafine grained aluminum 6061 sheets by asymmetric cryorolling for microforming

The size effect on the mechanism of fracture in ultrafine grained sheets is an unsolved problem in microforming. This paper describes a tensile test carried out to study the fracture behavior and the shear fracture angles of both rolled and aged ultrafine grained aluminum 6061 sheets produced by asymmetric cryorolling. A scanning electron microscope was used to observe the fracture surface. The finite element method was used to simulate the tensile test using the uncoupled Cockcroft–Latham and Tresca criteria and the coupled Gurson–Tvergaard–Needleman damage criterion. It was found that the shear fracture angle decreases gradually from 90° to 64° with an increasing number of passes. The results of simulations using the Gurson–Tvergaard–Needleman criterion show trends similar to the experimental ones. The paper also presents a discussion on the fracture mechanism and the size effect during the tensile test.

A new insight into ductile fracture of ultrafine-grained Al-Mg alloys

It is well known that when coarse-grained metals undergo severe plastic deformation to be transformed into nano-grained metals, their ductility is reduced. However, there are no ductile fracture criteria developed based on grain refinement. In this paper, we propose a new relationship between ductile fracture and grain refinement during deformation, considering factors besides void nucleation and growth. Ultrafine-grained Al-Mg alloy sheets were fabricated using different rolling techniques at room and cryogenic temperatures. It is proposed for the first time that features of the microstructure near the fracture surface can be used to explain the ductile fracture post necking directly. We found that as grains are refined to a nano size which approaches the theoretical minimum achievable value, the material becomes brittle at the shear band zone. This may explain the tendency for ductile fracture in metals under plastic deformation.

An Investigation of Interface Bonding of Bimetallic Foils by Combined Accumulative Roll Bonding and Asymmetric Rolling Techniques

The bond strength in bimetallic materials is an important material characteristic. In this study, 0.1-mm thick bimetallic foils (AA1050/AA6061) were produced using one pass of accumulative roll bonding followed by three passes of asymmetric rolling (AR). The AR passes were carried out at roll speed ratios of 1.0, 1.1, 1.2, 1.3, and 1.4 separately. Finite element simulation was used to model the deformation of the bimetallic foils for the various experimental conditions. Particular attention was focused on the bonding of the interface between AA1050 and AA6061 layers in the simulation. The optimization of the roll speed ratio was obtained for improvement of the bond strength of the interface of AA1050/AA6061 bimetallic foils during AR process. In the simulation, the mean equivalent strain at the interface zone between the AA1050 and AA6061 layers was seen to reach a peak value at a roll speed ratio of about 1.2 to 1.3, which also corresponded to a high quality bond at the interface as observed experimentally.

Optimisation of dispersion parameters of Gaussian plume model for CO2 dispersion

The carbon capture and storage (CCS) and enhanced oil recovery (EOR) projects entail the possibility of accidental release of carbon dioxide (CO2) into the atmosphere. To quantify the spread of CO2 following such release, the ‘Gaussian’ dispersion model is often used to estimate the resulting CO2 concentration levels in the surroundings. The Gaussian model enables quick estimates of the concentration levels. However, the traditionally recommended values of the ‘dispersion parameters’ in the Gaussian model may not be directly applicable to CO2 dispersion. This paper presents an optimisation technique to obtain the dispersion parameters in order to achieve a quick estimation of CO2 concentration levels in the atmosphere following CO2 blowouts. The optimised dispersion parameters enable the Gaussian model to produce quick estimates of CO2 concentration levels, precluding the necessity to set up and run much more complicated models. Computational fluid dynamics (CFD) models were employed to produce reference CO2 dispersion profiles in various atmospheric stability classes (ASC), different ‘source strengths’ and degrees of ground roughness. The performance of the CFD models was validated against the ‘Kit Fox’ field measurements, involving dispersion over a flat horizontal terrain, both with low and high roughness regions. An optimisation model employing a genetic algorithm (GA) to determine the best dispersion parameters in the Gaussian plume model was set up. Optimum values of the dispersion parameters for different ASCs that can be used in the Gaussian plume model for predicting CO2 dispersion were obtained.

High Strength and Ductility of Ultrathin Laminate Foils Using Accumulative Roll Bonding and Asymmetric Rolling

As product miniaturization is becoming widely popular, many microparts are being produced by microforming of sheets/foils, whose strength needs to be able to maintain structural stability of the micro-components. In addition, their strength and ductility of foils generally reduce with a reduction in the thickness due to the size effect. In this paper, we report the fabrication of an aluminum laminate foil using a combined process of accumulative roll bonding (ARB) and asymmetric rolling (AR). It was found that this improves both strength and ductility. TEM results show that the laminate structures produced by ARB develop an inhomogeneous microstructure with nanoscale grains and abnormal coarsening in some grains during AR processing. Both these effects result in an improved ductility and strength. Using these rolled products, micro-cups of very small wall thickness/cup diameter ratio (1/200) have been successfully fabricated by micro-deep drawing without the need for annealing.

Investigation of the Effects of Pipe Wall Roughness and Pipe Diameter on the Decompression Wave Speed in Natural Gas Pipelines

The shock tube experimental results have shown clearly that the decompression wave was slowed down in a pipe with a rough inner surface relative to that in a smooth pipe under comparable conditions. In the present paper a one-dimensional dynamic simulation model, named EPDECOM, was developed to investigate the effects of pipe wall roughness and pipe diameter on the decompression wave speed. Comparison with experimental results showed that the inclusion of frictional effects led to a better prediction than that of the widely used model implemented in GASDECOM. EPDECOM simulation results showed that the effect of roughness on the decompression wave speed is significant for pipe diameters less than 250 mm. However the decompression wave speed is nearly independent of the roughness for diameters above 250 mm as the frictional effect becomes negligible at such diameters.Copyright

Simultaneous Grain Growth and Grain Refinement in Bulk Ultrafine-Grained Copper under Tensile Deformation at Room Temperature

Grain growth and grain refinement behavior during deformation determine the strength and ductility of ultrafine-grained materials. We used asymmetric cryorolling to fabricate ultrafine-grained copper sheets with an average grain width of 230 nm and having a laminate structure. The sheets show a high-true failure strain of 1.5. Observation of the microstructure at the fracture surface reveals that ultrafine laminate-structured grains were simultaneously transformed into both equiaxed nanograins and coarse grains under tensile deformation at room temperature.