The Migration of High Angle Grain Boundaries during Recrystallization

When plastically deformed metallic materials are annealed, new strain free grains emerge from the microstructure and grow by means of grain boundary migration until the deformation microstructure is eliminated. This process is called recrystallization. In this paper the various methods by which grain boundary migration rates are measured stereologically in order to characterize the growth process are described and compared using illustrations from recrystallization experiments on commercial AA1050 aluminum. It seems abundantly clear that during recrystallization of cold-deformed materials, isothermal grain boundary migration rates decrease with time and reasons for such a decrease are discussed. A new methodology whereby migration rates of the individual recrystallization texture components may be quantified by combining stereology and orientation imaging by the electron back scattered pattern analysis is outlined. By illustration, recent experiments on aluminum and copper are summarized documenting the slight growth rate advantage the cube texture component (001)[100] possesses during recrystallization of cold rolled material. The role of orientation pinning effects on grain boundary migration is described briefly. It appears that such pinning effects allow recrystallized grains emerging from the weaker deformation texture components to enjoy an average growth rate advantage over those emerging from the stronger deformation texture components.     

Grain boundary curvature and grain growth kinetics with particle pinning

Second-phase particles are used extensively in design of polycrystalline materials to control the grain size. According to Zener’s theory, a distribution of particles creates a pinning pressure on a moving grain boundary. As a result, a limiting grain size is observed, but the effect of pinning on the detail of grain growth kinetics is less known. The influence of the particles on the microstructure occurs in multiple length scales, established by particle radius and the grain size. In this article, we use a meso-scale phase-field model that simulates grain growth in the presence of a uniform pinning pressure. The curvature of the grain boundary network is measured to determine the driving pressure of grain growth in 2D and 3D systems. It was observed that the grain growth continues, even under conditions where the average driving pressure is smaller than the pinning pressure. The limiting grain size is reached when the maximum of driving pressure distribution in the structure is equal to the pinning pressure. This results in a limiting grain size, larger than the one predicted by conventional models, and further analysis shows consistency with experimental observations. A physical model is proposed for the kinetics of grain growth using parameters based on the curvature analysis of the grain boundaries. This model can describe the simulated grain growth kinetics.     

Threshold stress for superplasticity in solid solution magnesium alloys

The effect of alloying elements on the threshold stress for superplasticity was investigated using two binary solid solutions, namely, Mg–Al and Mg–Y alloys. Both alloys exhibited superplasticity, and in spite of the absence of fine particles showed threshold-stress-like behavior. Different origins were suggested for the threshold-stress-like behavior after considering grain growth during deformation. The threshold-stress-like behavior in Mg–Al alloys originates from the effects of microstructural instability (grain-growth hardening). On the other hand, analysis of grain-boundary segregation suggested that the threshold-stress-like behavior in Mg–Y alloy originates from the segregation of yttrium in grain boundaries and its interaction with grain-boundary dislocations.     

A thermally activated dislocation-based constitutive flow model of nanostructured FCC metals involving microstructural evolution

Abstract

Due to their interface and nanoscale effects associated with structural peculiarities of nanostructured, face-centered-cubic (FCC) ultrafine-grained/nanocrystalline (UFG/NC) metals, in particular nanotwinned (NT) metals exhibit unexpected deformation behaviours fundamentally different from their coarse-grained (CG) counterparts. These internal boundaries, including grain boundaries and twin boundaries in UFG/NC metals, strongly interact with dislocations as deformation barriers to enhance the strength and strain rate sensitivity (SRS) of materials on the one hand, and play critical roles in their microstructural evolution as dislocation sources/sinks to sustain plastic deformation on the other. In this work, building on the findings of twin softening and (de)twinning-mediated grain growth/refinement in stretched free-standing NT–Ni foils, a constitutive model based on the thermally activated depinning process of dislocations residing in boundaries has been proposed to predict the steady-state grain size and simulate the plastic flow of NT–Ni, by considering the blocking effects of nanotwins on the absorption of dislocations emitted from boundaries. It is uncovered that the stress ratio (η_stress) of effective-to-internal stress can be taken as a signature to estimate the stability of microstructures during plastic deformation. This model not only reproduces well the plastic flow of the stretched NT–Ni foils as well as reported NT–Cu and the steady-state grain size, but also sheds light on the size-dependent SRS and failure of FCC UFG/NC metals. This theoretical framework offers the opportunity to tune the microstructures in the polycrystalline materials to synthesise high performance engineering materials with high strength and great ductility.     

Grain Boundary Dynamics: A Novel Tool for Microstructure Control

The reaction of grain boundaries to a wide spectrum of forces is reviewed. Curvature, volume energy and mechanical forces are considered. The boundary mobility is strongly dependent on misorientation, which is attributed to both grain boundary structure and segregation. In magnetically anisotropic materials grain boundaries can be moved by magnetic forces. For the first time a directionality of boundary mobility is reported. Flat boundaries can also be moved by mechanical forces, which sheds new light on microstructure evolution during elevated temperature deformation. Curvature driven and mechanically moved boundaries can behave differently. A sharp transition between the small and large angle boundary regime is observed. It is shown that grain boundary triple junctions have a finite mobility and thus, may have a serious impact on grain growth in fine grained materials. The various dependencies can be utilized to influence grain boundary motion and thus, microstructure evolution during recrystallization and grain growth.     

Grain boundaries of nanocrystalline materials – their widths, compositions, and internal structures

Nanocrystalline materials contain many atoms at and near grain boundaries. Sufficient numbers of Mössbauer probe atoms can be situated in grain boundary environments to make a clear contribution to the measured Mössbauer spectrum. Three types of measurements on nanocrystalline materials are reported here, all using Mössbauer spectrometry in conjunction with X-ray diffractometry, transmission electron microscopy, or small angle neutron scattering. By measuring the fraction of atoms contributing to the grain boundary component in a Mössbauer spectrum, and by knowing the grain size of the material, it is possible to deduce the average width of grain boundaries in metallic alloys. It is found that these widths are approximately 0.5 nm for fcc alloys and slightly larger than 1.0 nm for bcc alloys. Chemical segregation to grain boundaries can be measured by Mössbauer spectrometry, especially in conjunction with small angle neutron scattering. Such measurements on Fe-Cu and Fe₃Si-Nb were used to study how nanocrystalline materials could be stabilized against grain growth by the segregation of Cu and Nb to grain boundaries. The segregation of Cu to grain boundaries did not stabilize the Fe-Cu alloys against grain growth, since the grain boundaries were found to widen and accept more Cu atoms during annealing. The Nb additions to Fe₃Si did suppress grain growth, perhaps because of the low mobility of Nb atoms, but also perhaps because Nb atoms altered the chemical ordering in the alloy. The internal structure of grain boundaries in nanocrystalline materials prepared by high-energy ball milling is found to be unstable against internal relaxations at low temperatures. The Mössbauer spectra of the nanocrystalline samples showed changes in the hyperfine fields attributable to movements of grain boundary atoms. In conjunction with SANS measurements, the changes in grain boundary structure induced by cryogenic exposure and annealing at low temperature were found to be somewhat different. Both were consistent with a sharper density gradient between the crystalline region and the grain boundary region.     

Current problems of superplasticity

The possibility of conversion of intermetallic materials (Ti-Al, Fe-Cr-Co and Mn-Al-C) into the superplastic state is shown. The microstructural changes occurring during the superplastic flow in the Ti-Al intermetallics are analysed. A very important role of grain boundary structure in the superplastic deformation of intermetallics is shown. The experimental results obtained are interpreted on the basis of a model taking into account interactions between lattice dislocations and grain boundaries during the superplastic deformation.     

A model of grain refinement and strengthening of Al alloys due to cold severe plastic deformation

This paper presents a model which quantitatively predicts grain refinement and strength/hardness of Al alloys after very high levels of cold deformation through processes including cold rolling, equal channel angular pressing (ECAP), multiple forging (MF), accumulative roll bonding (ARB) and embossing. The model deals with materials in which plastic deformation is exclusively due to dislocation movement within grains, which is in good approximation the case for many metallic alloys at low temperature, for instance aluminium alloys. In the early stages of deformation, the generated dislocations are stored in grains and contribute to overall strength. With increase in strain, excess dislocations form and/or move to new cell walls/grain boundaries and grains are refined. We examine this model using both our own data as well as the data in the literature. It is shown that grain size and strength/hardness are predicted to a good accuracy.     

Modelling and simulation of dynamic recrystallisation based on multi-phase-field and dislocation-based crystal plasticity models

ABSTRACT

The mechanical properties of metals used as structural materials are significantly affected by hot (or warm) plastic working. Therefore, it is industrially important to predict the microscopic behaviour of materials in the deformation process during heat treatment. In this process, a number of nuclei are generated in the vicinity of grain boundaries owing to thermal fluctuation or the coalescence of subgrains, and dynamic recrystallisation (DRX) occurs along with the deformation. In this paper, we develop a DRX model by coupling a dislocation-based crystal plasticity model and a multi-phase-field (MPF) model through the dislocation density. Then, the temperature dependence of the hardening tendency in the recrystallisation process is introduced into the DRX model. A multiphysics simulation for pure Ni is conducted, and then the validity of the DRX model is investigated by comparing the numerical results of microstructure formation and the nominal stress–strain curve during DRX with experimental results. The obtained results indicate that in the process of DRX, nucleation and grain growth occur mainly around grain boundaries with high dislocation density. As deformation progresses, new dislocations pile up and subsequent nucleation occurs in the recrystallised grains. The influence of such microstructural evolution appears as oscillation in the stress–strain curve. From the stress–strain curves, the temperature dependence in DRX is observed mainly in terms of the yield stress, the hardening ratio, and the change in the hardening tendency after nucleation occurs.     

Channelling of Plastic Deformation by Interfaces in TiAl Intermetallics

Plastic deformation in the lamellar microstructure of the L1₀ tetragonal phase is strongly affected by special rotational lamellar interfaces on the {111} close packed planes and by general grain boundaries separating the lamellar colonies. The activity of possible deformation modes in Ti-rich TiAl alloys is explained considering in addition to generally known asymmetry of deformation twinning the asymmetry of superdislocation motion. The restrictions imposed on the direction of propagating deformation by the lamellar interfaces are analysed in detail. Even in the case when the transfer of plastic deformation across the interfaces does not occur, the presence of interfaces as strong obstacles to moving dislocations and deformation twins can lead to localisation of strain parallel to the lamellae, to so called channelling of deformation. General grain boundaries can also significantly influence plastic deformation by stress redistribution due to the compatibility stresses arising from the crystal elastic anisotropy and from the anisotropy of plastic deformation.     

Anisotropy of exchange stiffness and its effect on the properties of magnets

Using the spin-spiral formulation of the tight-binding linear muffin-tin orbital method, the principal components of the exchange stiffness tensor are calculated for typical hard magnets including tetragonal CoPt-type and hexagonal YCo₅ alloys. The exchange stiffness is strongly anisotropic in all studied alloys. This anisotropy makes the domain wall surface tension anisotropic. Competition between this anisotropic surface tension and magnetostatic energy controls the formation and dynamics of nanoscale domain structures in hard magnets. Anisotropic domain wall bending is described in detail from the general point of view and with application to cellular Sm–Co magnets. It is shown that the repulsive cell-boundary pinning mechanism in these magnets is feasible only due to the anisotropic exchange stiffness if suitably oriented initial pinning centers are available. In polytwinned CoPt-type magnets the exchange stiffness anisotropy controls the orientation of macrodomain wall segments. These segments may reorient both statically during microstructural coarsening and dynamically during the macrodomain wall splitting in external field. Reorientation of segments may facilitate their pinning at antiphase boundaries.     

Evolution of texture and grain boundary microstructure in two-phase (α + β) brass during recrystallization

The evolution of texture and microstructure during recrystallization is studied for two-phase copper alloy (Cu–40Zn) with a variation of the initial texture and microstructure (hot rolled and solution treated) as well as the mode of rolling (deformation path: uni-directional rolling and cross rolling). The results of bulk texture have been supported by micro-texture and microstructure studies carried out using electron back scatter diffraction (EBSD). The initial microstructural condition as well as the mode of rolling has been found to alter the recrystallization texture and microstructure. The uni-directionally rolled samples showed a strong Goss and BR {236}?385? component while a weaker texture similar to that of rolling evolved for the cross-rolled samples in the α phase on recrystallization. The recrystallization texture of the β phase was similar to that of the rolling texture with discontinuous ?101? α and {111} γ fiber with high intensity at {111}?101?. For a given microstructure, the cross-rolled samples showed a higher fraction of coincident site lattice Σ3 twin boundaries in the α phase. The higher fraction of Σ3 boundaries is explained on the basis of the higher propensity of growth accidents during annealing of the cross-rolled samples. The present investigation demonstrates that change in strain path, as introduced during cross-rolling, could be a viable tool for grain boundary engineering of low SFE fcc materials.     

A study of the hot and cold deformation of twin-roll cast magnesium alloy AZ31

Recent advances in twin-roll casting (TRC) technology of magnesium have demonstrated the feasibility of producing magnesium sheets in the range of widths needed for automotive applications. However, challenges in the areas of manufacturing, material processing and modelling need to be resolved in order to fully utilize magnesium alloys. Despite the limited formability of magnesium alloys at room temperature due to their hexagonal close-packed crystalline structure, studies have shown that the formability of magnesium alloys can be significantly improved by processing the material at elevated temperatures and by modifying their microstructure to increase ductility. Such improvements can potentially be achieved by processes such as superplastic forming along with manufacturing techniques such as TRC. In this work, we investigate the superplastic behaviour of twin-roll cast AZ31 through mechanical testing, microstructure characterization and computational modelling. Validated by the experimental results, a novel continuum dislocation dynamics-based constitutive model is developed and coupled with viscoplastic self-consistent model to simulate the deformation behaviour. The model integrates the main microstructural features such as dislocation densities, grain shape and grain orientations within a self-consistent viscoplasticity theory with internal variables. Simulations of the deformation process at room temperature show large activity of the basal and prismatic systems at the early stages of deformation and increasing activity of pyramidal systems due to twinning at the later stages. The predicted texture at room temperature is consistent with the experimental results. Using appropriate model parameters at high temperatures, the stress–strain relationship can be described accurately over the range of low strain rates.     

Sintering behavior and PTCR properties of stoichiometric blend BaTiO3

Donor doped positive temperature coefficient of resistivity barium titanate is highly sensitive to minor changes in processing conditions, Ba/Ti ratio, and dopant concentration. This leads to a lack of reproducibility of properties and microstructure. This study was performed in an effort to obtain a more microstructurally stable PTCR material. Barium titanate ceramics were prepared by blending Ba-excess BaTiO₃ powder with Ti-excess powder, in different ratios. Such donor modified blended systems display uniform, medium grain size (4-6 μm), high-density microstructures which are more stable to changes in processing parameters. The microstructures are characterized by flat grain edges, large grain-to-grain contact area and high degree of domain coherence across grain boundaries. The PTCR effect was, however, measured to be nominal in these samples. This has been attributed to the presence of a smaller barrier potential, and such microstructural features as strong domain coherence across grain boundaries, large grain-to-grain contact area, and high density. It was found that the simple act of blending donor doped BaTiO₃ powders of different Ba/Ti ratios drastically changes both microstructure and electrical properties. Blending results in the suppression of liquid-phase induced anomalous grain growth, suppressing grain growth processes and allowing sintering processes to go to a greater degree of completion. The proposed mechanism whereby this happens is that the presence of the donor in blended systems either changes the kinetics of liquid-phase formation and/or the wettability of grains, affecting liquid-phase distribution.     

Recent results on the generation of new orientations during recrystallization

In the last years High Voltage Electron Microscopy and Beck-experiments have been used in Göttingen to elucidate the generation of new orientations during the anneal of a deformed metal single crystal. It is found on Al, Cu and dilute Cu-P solid solutions that nucleation always occurs in orientations of the deformation microstructure. During growth orientations change by multiple twinning to produce grain boundaries of lower energy. These are not always the most mobile ones except in some alloys. The influence of such a growth selection on texture is discussed.This summary is based on the careful work of and lively discussion with the Göttingen RX group of P. Wilbrandt, A. Berger, F. Ernst and U. Klement. It is supported by DFG.     

Wetting of grain boundaries by the second solid phase in Al-based alloys

This work presents data on changes in the structure and properties of aluminum-based alloys subjected to severe plastic deformation by high-pressure torsion. Microstructure and the composition and change in temperature for phases are studied for double (Al-Zn, Al-Mg) and ternary (Al-Mg-Zn) alloys. Tie-lines of the liquid phase wetting of grain boundaries and grain boundary solvus lines are constructed on phase diagrams of our Al-Zn and Al-Mg systems. The shifting of the phase composition in the bulk of aluminum grains from the Al + τ region to the Al + η region of the Al-Mg-Zn phase diagram with an increase in the specific area of grain boundaries is described.     

Strength and plastic deformation of polycrystalline diamond composites

ABSTRACT

The use of nanopolycrystalline diamond has allowed a systematic study on deformation of polycrystalline diamond composites (PCDCs). Bulk PCDCs samples containing either Co or SiC as a binding agent were deformed under high pressure and temperature to strains up to 18% at strain rates ～10^?5?s^?1. All samples exhibit strong work hardening. The strength of PCDCs depends on the amount and type of binding agents and is consistently weaker than that of diamond single crystals. The weakening may be due to the binder materials, which play an important role in affecting grain boundary structures. In SiC-based PCDC, significant grain fragmentation occurs. Nearly all grain boundaries are wetted by SiC after large deformation, resulting in lower strength. In Co-based PCDC, the microstructure is dominated by dislocations, deformation twins, and separated grain boundaries. The density of deformation twins increases significantly with strain, with the twin domain width reaching as low as 10–20?nm at 14% strain.     

Heterogeneous ceramics formed by grain boundary engineering

Two examples were selected to emphasize the potential of grain boundary engineering in the performance design of heterogeneous ceramics. Gadolinium-doped ceria-based powders were co-fired with additions of silica, and silica and lanthanum oxide, to test the silica scavenging role of lanthanum. The formation of one ionic conducting secondary phase, instead of an insulating phase, was attempted. The structural, microstructural, and electrical characterization of these samples confirmed the formation of one apatite-type lanthanum silicate-based phase and a significant enhancement of the grain boundary conductivity of these materials. One second approach addressed the formation of one mixed conductor, with electronically conductive grain boundaries, surrounding the grains of one lanthanum gallate-based electrolyte (core-shell type microstructure). Fe-doped grain boundaries were formed by selective Fe-diffusion (thermally assisted) from lanthanum ferrite screen printed layers. Combined microstructural and electrical characterization showed that the adopted solution was also effective.     

Changes in the diffusion properties of nonequilibrium grain boundaries upon recrystallization and superplastic deformation of submicrocrystalline metals and alloys

The effect of an increase in the coefficient of the grain-boundary diffusion upon recrystallization and superplastic deformation of submicrocrystalline (SMC) materials prepared by severe plastic deformation has been studied. It is shown that the coefficient of the grain-boundary diffusion of the SMC materials is dependent on the intensity of the lattice dislocation flow whose value is proportional to the rate of the grain boundary migration upon annealing of SMC metals or the rate of the intragrain deformation under conditions of superplastic deformation of SMC alloys. It is found that, at a high rate of grain boundary migrations and high rates of superplastic deformation, the intensity of the lattice dislocation flow bombarding grain boundaries of SMC materials is higher than the intensity of their diffusion accommodation, which leads to an increase in the coefficient of the grain-boundary diffusion and a decrease in the activation energy. The results of the numerical calculations agree well with the experimental data.