N. Mortazavi

Deformation and texture evolution of OFHC copper during dynamic tensile extrusion

During dynamic tensile extrusion (DTE) the material is subjected to a complex deformation history, including high strain rates, large strains and elevated temperatures. This technique provides unique means to explore material performance under extreme conditions. In this work, the microstructural evolution of 99.98% commercially pure copper during the DTE test was investigated by means of electron backscatter diffraction (EBSD). The investigation was focused on the segment of the extruded jet that remained in the die, since numerical simulation showed that material points along the longitudinal axis of such segment correspond to different stages of a common temperature compensated deformation history. Therefore, post mortem microstructure information extracted at different locations along the center line is equivalent to in situ real-time measurement during the deformation process. EBSD investigations along the center line showed a progressive elongation of the grains, and an accompanying development of a strong 〈0 0 1〉 + 〈1 1 1〉 dual fiber texture. Meta-dynamic discontinuous dynamic recrystallization (DRX) occurred at larger strains, and it was demonstrated that nucleation occurred during straining, while subsequent grain growth took place during post-deformation cooling in the die. According to strain energy minimization arguments, the recrystallization resulted in an increased 〈0 0 1〉 texture component. The critical strain for recrystallization was well predicted from a power-law dependence on the Zener–Hollomon parameter, including grain size dependence and a temperature dependent activation energy. In addition, it was shown that 〈0 0 1〉 and 〈1 1 1〉oriented grains develop different dislocation substructures during straining, exhibiting elongated cells/micro-bands and typical cell structures, respectively. The present results also confirm that dynamic tensile ductility increases with decreasing initial grain size as a result of grain refinement and lowering of dislocation and twin densities during DRX.

On the capability of in-situ exposure in an environmental scanning electron microscope for investigating the atmospheric corrosion of magnesium

The feasibility of environmental scanning electron microscope (ESEM) in studying the atmospheric corrosion behavior of 99.97% Mg was investigated. For reference, ex-situ exposure was performed. A model system was designed by spraying few salt particles on the metal surface and further promoting the corrosion process using platinum (Pt) deposition in the form of 1×1×1 µm(3) dots around the salt particles to create strong artificial cathodic sites. The results showed that the electron beam play a significant role in the corrosion process of scanned regions. This was attributed to the irradiation damage occurring on the metal surface during the ESEM in-situ experiment. After achieving to a reliable process route, in a successful attempt, the morphology and composition of the corrosion products formed in-situ in the ESEM were in agreement with those of the sample exposed ex-situ.

Interplay of water and reactive elements in oxidation of alumina-forming alloys

High-temperature alloys are crucial to many important technologies that underpin our civilization. All these materials rely on forming an external oxide layer (scale) for corrosion protection. Despite decades of research on oxide scale growth, many open questions remain, including the crucial role of the so-called reactive elements and water. Here, we reveal the hitherto unknown interplay between reactive elements and water during alumina scale growth, causing a metastable ‘messy’ nano-structured alumina layer to form. We propose that reactive-element-decorated, hydroxylated interfaces between alumina nanograins enable water to access an inner cathode in the bottom of the scale, at odds with the established scale growth scenario. As evidence, hydride-nanodomains and reactive element/hydrogen (deuterium) co-variation are observed in the alumina scale. The defect-rich alumina subsequently recrystallizes to form a protective scale. First-principles modelling is also performed to validate the RE effect. Our findings open up promising avenues in oxidation research and suggest ways to improve alloy properties.The crucial interaction between reactive elements and water vapour during the oxide scale growth of alumina-forming alloys is revealed, providing insights to improve corrosion resistance of high-temperature alloys.

Validating material modelling for OFHC copper using Dynamic Tensile Extrusion (DTE) test at different velocity impact

In the Dynamic Tensile Extrusion (DTE) test, the material is subjected to very large strain, high strain rate and elevated temperature. Numerical simulation, validated comparing with measurements obtained on soft-recovered extruded fragments, can be used to probe material response under such extreme conditions and to assess constitutive models. In this work, the results of a parametric investigation on the simulation of DTE test of annealed OFHC copper -at impact velocity ranging from 350 up to 420 m/s -using the modified Rusinek-Klepaczko model, are presented. Simulation of microstructure evolution was performed using the visco-plastic self consistent model (VPSC), providing, as input, the velocity gradient history obtained with FEM at selected locations along the axis of the fragment trapped in the extrusion die. Finally, results are compared with EBSD analysis.

Modelling and simulation of dynamic recrystallization (DRX) in OFHC copper at very high strain rates

At high strain rates, deformation processes are essentially adiabatic and if the plastic work is large enough dynamic recrystallization can occur. In this work, an examination on microstructure evolution of OFHC copper in Dynamic Tensile Extrusion (DTE) test, performed at 400 m/s, was carried out. EBSD investigations, along the center line of the fragment remaining in the extrusion die, showed a progressive elongation of the grains, and an accompanying development of a strong + dual fiber texture. Discontinuous dynamic recrystallization (DRX) occurred at larger strains, and it was showed that nucleation occurred during straining. A criterion for DRX to occur, based on the evolution of Zener-Hollomon parameter during the dynamic deformation process, is proposed. Finally, DTE test was simulated using the modified Rusinek-Klepaczko constitutive model incorporating a model for the prediction of DRX initiation.

Effects of cold working and heat treatment on microstructure and wear behaviour of Cu–Be alloy C17200

The effects of cold work process between aging and solution heat treatment on the microstructure, hardness and the tribologic behaviour of a copper–beryllium (Cu–Be) alloy C17200 were investigated. The wear behaviour of the alloys was studied using ‘pin on disc’ method under dry conditions. The results show that the formation of fine grained structure and γ phase particles enhances the mechanical properties of the alloy; nonetheless, they do not reduce the wear rate. This is attributed to the capability of the softer specimens to maintain oxygen rich compounds during the dry sliding test.

Development of advanced hybrid materials with the help of pulse electrodeposition

Pulse electrodeposition has been applied to enhance properties of two different types of lightweight construction materials, a periodic cellular material (PCM) and a micro-sandwich. For the PCM, the deformation behaviour of the nanocrystalline Ni-18 wt-% Fe sleeve material (bulk samples) has been investigated up to 548 K. The material exhibits plasticity of >30% fracture strain at higher temperatures (423 K) compared to < 15% at room temperature (295 K). TEM characterisation shows that coarser grains are present, which enable strain hardening by intra-granular dislocation accumulation. This leads to larger fracture strains at higher temperatures. Hence, for allowing application of the PCM at elevated temperatures (e.g. at temperatures of more than 400 K), the sleeve material has to be stabilised against deformation-induced grain growth. For the micro-sandwich, the ∼100 μm thick pulse-electrodeposited nickel coating on either the face sheets or polymer fibres of the sandwich core can provide extra strength. With respect to the fibres, the plating process needs to be improved further to achieve a continuous and homogeneous coating.