Sergey Malopheyev

Ultrafine-Grained Structure Produced by FSW and ECAP in Al-Mg-Sc-Zr Alloy: Comparison

The Al-5.4Mg-0.2Sc-0.1Zr alloy with initial coarse grained structure and containing coherent nanoscale Al3(Sc,Zr) particles with an average size of ~9 nm was subjected to equal channel angular pressing (ECAP) at temperatures ranging from 300 to 450°C up to a total strain of ~12 and friction stir processing (FSP) with the rotation speed ranging from 350 to 800 rpm. ECAP led to the formation of a uniform microstructure with an average grain size of ~ 0.9 μm. Increasing deformation temperature leads to a slight increase in the average grain size to 1.4 μm and coarsening of Al3(Sc,Zr) precipitates to 13 nm. FSP with a tool rotation speed of 350, 500, 650, 800 rpm and traveling speed of 75 mm/min led to the formation of fully recrystallized uniform microstructures with an average grain size of ~1.6, 1.9, 2.7 and 2.9 μm, respectively. The coarsening of Al3(Sc,Zr) dispersoids from 9 to 27 nm occurred under FSP but most of them retained coherency with the matrix.

The Role of Deformation Banding in Grain Refinement under ECAP

The mechanism of grain refinement in an Al-5.4Mg-0.4Mn-0.2Sc-0.09Zr alloy subjected to equal-channel angular pressing (ECAP) at 300°C through route BC is considered. It was shown that the formation of geometrically necessary boundaries (GNB) aligned with a {111} plane at ε≤1 initiates the occurrence of continuous dynamic recrystallization (CDRX). Upon further strain the GNBs transform to low-to-moderate angle planar boundaries that produces lamellar structure. In the strain interval 2-4, 3D arrays of planar boundaries evolve due to inducing the formation of 2nd order and higher orders families of GNBs in new {111} planes. GNBs gradually convert to high-angle boundaries (HAB) with strain. A uniform recrystallized structure is produced at a true strain of ∼8. The role of slip concentration and shearing patterns in the formation of GNBs is discussed.

Mechanisms of Dynamic Recrystallization in Aluminum Alloys

Mechanisms of dynamic recrystallization operating at severe plastic deformation in a wide temperature range are reviewed for aluminum alloys. The main mechanism of grain refinement in all aluminum alloys is continuous dynamic recrystallization (CDRX). Temperature, deformation process and distribution of secondary phases strongly affect the CDRX mechanism. Initial formation of geometrically necessary boundaries (GNBs) and a dispersion of nanoscale particles accelerate CDRX facilitating the formation of a 3D network of low-angle boundaries (LAB) followed by their gradual transformation to high-angle boundaries (HAB). At high and intermediate temperatures, 3D networks of LABs may evolve due to rearrangement of lattice dislocations by climb, and mutual intersection of GNB, respectively. At high temperatures, in aluminum alloys containing no nanoscale dispersoids the CDRX occurs through the impingement of initial boundaries forced by deformation-induced LABs. This recrystallization process is termed as geometric dynamic recrystallization (GDRX). At low temperatures, the extensive grain refinement occurs through a continuous reaction which is distinguished from CDRX by restricted rearrangement of lattice dislocation. Introduction of large misorientation may occur through the formation of 3D networks of GNBs, only.

Superplastic Behavior of Friction-Stir Welded Joints of an Al-Mg-Sc Alloy with Ultrafine-Grained Microstructure

The commercial Al-5.4Mg-0.2Sc-0.1Zr alloy was subjected to equal-channel angular pressing at 300°C to a true strain ~12 followed by cold rolling to a total thickness reduction of 80%. The ultrafine-grained sheets were joined by friction stir welding (FSW). To evaluate superplastic properties of the weldments, the tensile samples including all of the characteristic FSW microstructural zones were machined perpendicular to the welding direction and pulled up to failure in the temperature range of 400 to 500°C and at strain rates of 2.8×10-4 s-1 to 5.6×10-1 s-1. The friction-stir welded material exhibited excellent superplastic properties. The highest elongation-to-failure of ~1370% was recorded at a temperature of ~450°C and an initial strain rate of 5.6×10-2 s-1, where the strain rate sensitivity coefficient was about 0.64. The relationship between superplastic ductility and microstructure is discussed.

Effect of Extensive Isothermal Rolling on Microstructure and Mechanical Properties of an Al-Mg-Sc Alloy

The evolution of microstructure and mechanical properties of an Al-5.4Mg-0.4Mn-0.2Sc-0.09Zr alloy subjected to rolling at 300oC was studied. It was shown that the rolling of the alloy leads to strong anisotropy in mechanical properties. The formation of the lamellar structure occurs at a total reduction of 60% due to alignment of initial boundaries along rolling direction (RD), and appearance of geometrically necessary boundaries (GNB) aligned with {111} planes. This process is accompanied by a strong increase in the lattice dislocation density by a factor of 50. Further rolling induces the formation of subgrains within lamellar structure that diminishes the anisotropy. The GNBs have low-angle misorientations, initially. After a reduction of 80%, minor part of GNBs acquires high-angle misorientation. The formation of well-defined subgrains within lamellas leads to a decrease in the lattice dislocation density by a factor of about 10; the yield stress (YS) decrease is -25% along the RD. At the same time the YS in the transverse direction tends to increase with increasing reduction from 60 to 80%. The effect of the deformation structure on the mechanical properties and their anisotropy is discussed.

Mechanical Properties of an Al-5.4%Mg-0.5%Mn-0.1%Zr Alloy Subjected to ECAP and Rolling

Superplasticity and microstructural evolution of a commercial Al-5.4%Mg-0.5%Mn-0.1%Zr alloy subjected to severe plastic deformation through equal-channel angular pressing (ECAP) and subsequent rolling was studied in tension at strain rates ranging from 1.4×10-4 to 5.6×10-2 s-1 in the temperature interval 400-550°C. The alloy had an unrecrystallized microstructure with an average crystallite size less than 5 m. The alloy exhibited the yield strength of ~370 MPa, ultimate strength of ~450 MPa and elongation-to-failure of ~15% at ambient temperature. In spite of small crystallite size the alloy shows moderate superplastic properties. The highest elongation-to-failures of ~450% appeared at a temperature of ~500°C and an initial strain rate of ~1.4×10-3 s-1, where the strain rate sensitivity coefficient, m, is of about 0.57. The relationship between superplastic ductilities and microstructure is discussed.

Mechanism of Grain Refinement during Equal-Channel Angular Pressing at Intermediate Temperature in an Al-Mg-Sc Alloy

The mechanism of grain refinement of an Al-5.4Mg-0.4Mn-0.2Sc-0.09Zr alloy subjected to equal-channel angular pressing (ECAP) with a back pressure (BP) for up to 12 passes via route BC at 573K (300 °C) was studied. New grains form through a specific mechanism of continuous dynamic recrystallization (CDRX). At the first pass of ECAP, formed geometrically necessary boundaries play a vital role in initiation of recrystallization process due to formation of planar lamellar structure. The second pass led to transformation of this planar to 3D net of sub-boundaries which are changes into high-angle boundaries at further deformation. The formation of primary MSBs is associated with the appearance of texture a-fiber, and the appearance of a new type of shear texture, which is an axial {112} texture of orientation around the transverse direction accompanies the formation of ultra-fine grains.

Effect of Rolling on Superplastic Behavior of an Al-Mg-Sc Alloy with Ultrafine-Grained Structure

The superplastic behavior of a commercial aluminum alloy denoted as 1570 Al with a chemical composition of Al-6%Mg-0.5%Mn-0.2%Sc-0.07%Zr (in wt. %) and ultrafine-grained (UFG) structure produced by equal channel angular pressing at 300°C to a true strain ~12 was studied after final cold or warm rolling. The tensile specimens were machined along rolling direction and pulled up to failure in the temperature range of 250 to 500°C at strain rates ranging from 10-4 s-1 to 10-1 s-1. The specimens produced by warm or cold rolling exhibit different superplastic behavior. The material subjected to warm rolling exhibits excellent superplastic properties; the highest elongation-to-failure of ~1970% was recorded at a temperature of ~450°C and an initial strain rate of 1.4×10-1 s-1. On the other hand, the material subjected to cold rolling demonstrates moderate superplastic properties; the highest elongation-to-failure of ~755% appears at a temperature of ~300°C and an initial strain rate of 1.4×10-2 s-1.

Friction-Stir Welding of Zr-Modified AA5083 Sheets in Different Conditions

The effect of friction-stir welding (FSW) on microstructure and mechanical properties of Zr-modified AA5083 aluminum alloy was studied. FSW was observed to lead to the formation of fully recrystallized ultrafine-grained microstructures and preservation of nanoscale dispersoids in stir zone. The joint efficiency of the friction-stir welds for ultimate tensile strength was found to be 94% and 74% in the hot-rolled and cold-rolled preprocessed material conditions. The stir zone microstructure was predicted to be stable against abnormal grain growth during post-weld heat treatment.

Superplasticity of Friction-Stir Welded Al-Mg-Sc Alloy with Ultrafine-Grained Microstructure Obtained by Warm Severe Plastic Deformation

High-strength sheets of Al-5.4Mg-0.2Sc-0.1Zr alloy were produced by equal-channel angular pressing (ECAP) to 12 passes via route BC at 300 °C (573 K) followed by isothermal rolling at 300 °C (573 K) to a total thickness reduction of 80%. The final sheets with ultra-fine grained (UFG) structure were joined by friction stir welding (FSW). The tensile samples including all of the characteristic FSW microstructural zones were machined perpendicular to welding direction. The material demonstrated excellent superplastic properties in the range of temperatures from 350 (623 K) to 450 °C (723 K) at strain rates ranging from 8.3×10-3 s-1 to 3.3×10-1 s-1. The base material was found to be prone to abnormal grain growth at the testing temperature. This led to localization of the superplastic deformation in the stir zone section of the joints and thus limited total elongation-to-failure. The relationship between superplastic ductility and microstructure and application of this technique for the fabrication of large-scale superplastic sheets are discussed.