Effect of microstructure on fracture in age hardenable Al alloys

ABSTRACT

In the present study, the fracture behaviour of AA6016 alloy was investigated during bending deformation. Wrap-bend tests were conducted and the material was subjected to different bend angles to study crack propagation. The average grain size of the as-received material is approximately 45?μm. The aspect ratio of the grains was changed from 0.53 to 0.40 during bending. The presence of deformation bands was observed during bending in both tensile and compressive regions of the sample. No orientation correlation was observed between the deformation band and its corresponding parent grain. The Schmid factor inside the deformation bands was higher than that of the parent grain, which indicates that the deformation bands accommodate strain during bending. The crystallographic texture evolved significantly during bending deformation. The strength of cube texture component decreases with increasing bend angle and new texture components formed during bending. These new texture components favour either single slip or duplex slip. A mixture of intra-granular and inter-granular fracture occurs during bending. It is observed that inter-granular crack propagation is predominantly favoured along high-angle boundaries, and grain boundary de-cohesion occurs in regions where the misorientation angle is greater than 40°. The formation of deformation-induced coincidence lattice site (CSL) boundaries is also observed during bending and it is shown that the volume fraction of CSL boundaries of Σ3 type increases with increasing bend angle. The current study shows that the formation of deformation-induced CSL boundaries of Σ3 type in AA6016 alloy can improve its inherent resistance to crack propagation during bending.     

Microstructure evolution during severe plastic deformation

Radiotracer diffusion studies of severely deformed, ultra-fine grained materials have revealed the presence of ultra-fast transport paths, which include “non-equilibrium” grain boundaries and free volume. Under some experimental conditions, percolating porosity is produced even in pure copper. Micro-cracks may form in metals, if the local maximum shear stress exceeds the shear yield stress. However, their growth and propagation is postponed till late in the deformation process owing to the ductility of metals, the hydrostatic component of the stress system and/or dynamic recovery/recrystallization. In other words, crack growth and propagation is present only when the scope for further deformation is highly restricted. Using this approach, the load required for equal channel angular pressing, the change in the slope of the Hall–Petch plot with decreasing grain size and the theoretical limit for the smallest grain size attainable in a metal in a severe plastic deformation process are predicted and validated by experimental results. Experimentally successful prevention of percolated crack formation by the superposition of a hydrostatic pressure is also accounted for using this model.     

Strain localisation in granular media

This paper discusses strain localisation in granular media by presenting experimental, full-field analysis of mechanical tests on sand, both at a continuum level, as well as at the grain scale. At the continuum level, the development of structures of localised strain can be studied. Even at this scale, the characteristic size of the phenomena observed is in the order of a few grains. In the second part of this paper, therefore, the development of shear bands within specimen of different sands is studied at the level of the individual grains, measuring grains kinematics with x-ray tomography. The link between grain angularity and grain rotation within shear bands is shown, allowing a grain-scale explanation of the difference in macroscopic residual stresses for materials with different grain shapes. Finally, rarely described precursors of localisation, emerging well before the stress peak are observed and commented.     

高温塑性变形引起的P非平衡晶界偏聚

阐述了高温塑性变形引起的非平衡晶界偏聚的准热力学和动力学,并使用该模型预测了低合金结构钢中高温塑性变形导致的P在奥氏体晶界的非平衡偏聚.研究发现：当变形为20%,应变速率为1×10^-3 s^-1时,在800 ℃左右会出现一个P的晶界偏聚浓度峰值;在1000 ℃变形为20％时,晶界偏聚浓度随着应变速率的增加而增加.预测结果与现有的实验结果基本一致. 关键词： 非平衡偏聚 晶界 塑性变形 磷     

Anisotropic rheology during grain boundary diffusion creep and its relation to grain rotation,grain boundary sliding and superplasticity

The response of periodic microstructures to deformation can be analysed rigorously and this provides guidance in understanding more complex microstructures. When deforming by diffusion creep accompanied by sliding, irregular hexagons are shown to be anisotropic in their rheology. Analytic solutions are derived in which grain rotation is a key aspect of the deformation. If grain boundaries cannot support shear stress, the polycrystal viscosity is extremely anisotropic. There are two orthogonal directions of zero strength: sliding and rotation cooperate to allow strain parallel to these directions to be accomplished without any dissolution or plating. When a linear velocity/shear stress relationship is introduced for grain boundaries, the anisotropy is less extreme, but two weak directions still exist along which polycrystal strength is controlled only by the grain boundary “viscosity”. Irregular hexagons are characterised by four parameters. A particular subset of hexagons defined by two parameters, which includes regular hexagons as well as some elongate shapes, shows singular behaviour. Grain shapes that are close to that of the subset may exhibit large grain rotation rates and have no well-defined rheology unless there is a finite grain boundary viscosity. This new analysis explains why microstructures based on irregular but near equiaxed grains show high rotation rates during diffusion creep and it provides a framework for understanding strength anisotropy during diffusion creep.     

Atomistic simulation of the stacking fault energy and grain shape on strain hardening behaviours of FCC nanocrystalline metals

ABSTRACT

Ultra-fine grained copper with nanotwins is found to be both strong and ductile. It is expected that nanocrystalline metals with lamella grains will have strain hardening behaviour. The main unsolved issues on strain hardening behaviour of nanocrystalline metals include the effect of stacking fault energy, grain shape, temperature, strain rate, second phase particles, alloy elements, etc. Strain hardening makes strong nanocrystalline metals ductile. The stacking fault energy effects on the strain hardening behaviour are studied by molecular dynamics simulation to investigate the uniaxial tensile deformation of the layer-grained and equiaxed models for metallic materials at 300?K. The results show that the strain hardening is observed during the plastic deformation of the layer-grained models, while strain softening is found in the equiaxed models. The strain hardening index values of the layer-grained models decrease with the decrease of stacking fault energy, which is attributed to the distinct stacking fault width and dislocation density. Forest dislocations are observed in the layer-grained models due to the high dislocation density. The formation of sessile dislocations, such as Lomer–Cottrell dislocation locks and stair-rod dislocations, causes the strain hardening behaviour. The dislocation density in layer-grained models is higher than that in the equiaxed models. Grain morphology affects dislocation density by influencing the dislocation motion distance in grain interior.     

Prediction of flow stress and textures of AZ31 magnesium alloy at elevated temperature

The viscoplastic behaviour of magnesium alloys at high temperatures leads to highly temperature-dependent mechanical properties. While at high strain rates a notable strain hardening response is observed, at low strain rates the material shows a smooth plastic response with negligible amount of hardening. This complicated behaviour is due to different deformation mechanisms that are active at different strain rate regimes, resulting in different strain rate sensitivity parameters. In this study we show, by utilizing both numerical simulations and experiments, that this behaviour can be predicted by a model that combines two deformation mechanisms, grain boundary sliding mechanism and dislocation glide mechanism. We discuss the importance of each deformation mechanism at different strain rate regimes based on the findings of modelling and experimental results for AZ3 magnesium alloy. By developing a model that includes the above-mentioned two deformation mechanism, the prediction of flow properties is expanded to a wide range of strain rate regimes compared to previous study. The obtained numerical findings for the stress–strain behaviour as well as texture evolution show good agreement with the experimental results.     

Contributions of different strengthening mechanisms to the shear strength of an extruded Mg–4Zn–0.5Ca alloy

The shear deformation behaviour of an extruded Mg–4Zn–0.5Ca alloy was studied using shear punch testing at room temperature. The extrusion process effectively refined the microstructure, leading to a grain size of 4.6 ± 1.4 μm. Contributions of different strengthening mechanisms to the room temperature shear yield stress, and overall flow stress of the material, were calculated. These mechanisms include dislocation strengthening, grain boundary strengthening, solid solution hardening and strengthening resulting from second-phase particles. Grain boundary strengthening and solid solution hardening made significant contributions to the overall strength of the material, while the contributions of second-phase particles and dislocations were trivial. The observed differences between calculated and experimental strength values were discussed based on the textural softening of the material.     

Non-planar grain boundary structures in fcc metals and their role in nano-scale deformation mechanisms

This work presents the results of a comparative molecular dynamics study showing that relaxed random grain boundary structures can be significantly non-planar at the nano-scale in fcc metals characterized by low stacking fault values. We studied the relaxed structures of random [1?1?0] tilt boundaries in a polycrystal using interatomic potentials describing Cu and Pd. Grain boundaries presenting non-planar features were observed predominantly for the Cu potential but not for the Pd potential, and we relate these differences to the stacking fault values. We also show that these non-planar structures can have a strong influence on dislocation emission from the grain boundaries as well as on grain boundary strain accommodation processes, such as grain boundary sliding. We studied the loading response in polycrystals of 40 nm grain size to a level of 9% strain and found that the non-planar grain boundaries favour dislocation emission as a deformation mechanism and hinder grain boundary sliding. This has strong implications for the mechanical behaviour of nano-crystalline materials, which is determined by the competition between dislocation activity and grain boundary accommodation of the strain. Thus, the two interatomic potentials for Cu and Pd considered in this work resulted in the same overall stress–strain curve, but significantly different fractions of the strain accommodated by the intergranular versus intragranular deformation mechanisms. Strain localization patterns are also influenced by the non-planarity of the grain boundary structures.     

The influence of Cd on the superplasticity of Zn-Al alloys

In the paper the results of the superplastic deformation study in the fine grained Zn-1·1 wt.% Al and Zn-0·35 wt.% Al — 0·25 wt.% Cd alloy are presented. The influence of the long-termed ageing at room temperature on the deformation characteristics is investigated and their changes are explained on the basis of the grain growth. The presence of Cd is found to increase the stability of the fine grained structure. The influence of strain rate is studied at 293 and 373 K. Both alloys exhibit superplastic properties with maximum ductilitiesA600% and maximum values of the parameterm0·5. The region of the best superplastic properties is shifted to slower strain rates as a consequence of the Cd atoms presence. The flow stress corresponding to a given strain rate is found to be much higher in the Zn-Al-Cd alloy. The grain boundary segregation of Cd atoms is suggested as a possible reason for better stability of the fine grained structure in the Zn-Al-Cd alloy as well as for the differences observed in the deformation behaviour of both alleys studied.     

温度和应变速率耦合作用下纳米晶Ni压缩行为研究

本文利用低温力学测试系统研究了电化学沉积纳米晶Ni在不同温度和宽应变速率条件下的压缩行为. 借助应变速率敏感指数、激活体积、扫描电子显微镜及高分辨透射电子显微镜方法, 对纳米晶Ni的压缩塑性变形机理进行了表征. 研究表明, 在较低温度条件下, 纳米晶Ni的塑性变形主要是由晶界位错协调变形主导, 晶界本征位错引出后无阻碍的在晶粒内无位错区运动, 直至在相对晶界发生类似切割林位错行为. 并且, 在协调塑性变形时引出位错的残留位错能够增加应变相容性和减小应力集中; 在室温条件下, 纳米晶Ni的塑性变形机理主要是晶界-位错协调变形与晶粒滑移/旋转共同主导. 利用晶界位错协调变形机理和残留位错运动与温度及缺陷的相关性揭示了纳米晶Ni在不同温度、不同应变速率条件下力学压缩性能差异的内在原因.     

Grain boundary engineering: fatigue fracture

Abstract

Grain boundary engineering has revealed significant enhancement of material properties by modifying the populations and connectivity of different types of grain boundaries within the polycrystals. The character and connectivity of grain boundaries in polycrystalline microstructures control the corrosion and mechanical behaviour of materials. A comprehensive review of the previous researches has been carried out to understand this philosophy. Present research thoroughly explores the effect of total strain amplitude on phase transformation, fatigue fracture features, grain size, annealing twinning, different grain connectivity and grain boundary network after strain controlled low cycle fatigue deformation of austenitic stainless steel under ambient temperature. Electron backscatter diffraction technique has been used extensively to investigate the grain boundary characteristics and morphologies. The nominal variation of strain amplitude through cyclic plastic deformation is quantitatively demonstrated completely in connection with the grain boundary microstructure and fractographic features to reveal the mechanism of fatigue fracture of polycrystalline austenite. The extent of boundary modifications has been found to be a function of the number of applied loading cycles and strain amplitudes. It is also investigated that cyclic plasticity induced martensitic transformation strongly influences grain boundary characteristics and modifications of the material’s microstructure/microtexture as a function of strain amplitudes. The experimental results presented here suggest a path to grain boundary engineering during fatigue fracture of austenite polycrystals.     

Cyclic deformation and fatigue cracking behaviour of polycrystalline Cu,Cu–10 wt% Zn and Cu–32 wt% Zn

The cyclic deformation behaviour of polycrystalline Cu, Cu–10 wt% Zn and Cu–32 wt% Zn was systematically investigated in the plastic strain amplitude range of 1 × 10^?4–4 × 10^?3. The differences in the cyclic stress–strain (CSS) responses and fatigue cracking behaviour between Cu, Cu–10 wt% Zn and Cu–32 wt% Zn were compared. It was found that the occurrence of a cyclic saturation for Cu–10 wt% Zn and Cu–32 wt% Zn strongly depends on the applied strain amplitude, whereas polycrystalline Cu always displays cyclic saturation. Surface deformation morphologies were analyzed by scanning electron microscopy (SEM). One of the major features observed is that the slip bands become increasingly homogenous with Zn addition. The fatigue cracks were found to frequently nucleate along the annealing twin boundaries (TBs) in Cu–10 wt% Zn and Cu–32 wt% Zn, but not in polycrystalline Cu. Based on these experimental results, the cyclic deformation response and fatigue cracking behaviour are discussed, and a developed TB cracking mechanism is proposed to explain the difference in fatigue cracking mechanisms in Cu, Cu–10 wt% Zn and Cu–32 wt% Zn.     

High-pressure torsion-induced grain growth and detwinning in cryomilled Cu powders

Two mechanisms for deformation-induced grain growth in nanostructured metals have been proposed, including grain rotation-induced grain coalescence and stress-coupled grain boundary (GB) migration. A study is reported in which significant grain growth occurred from an average grain size of 46?nm to 90?nm during high pressure torsion (HPT) of cryomilled nanocrystalline Cu powders. Careful microstructural examination ascertained that grain rotation-induced grain coalescence is mainly responsible for the grain growth during HPT. Furthermore, a grain size dependence of the grain growth mechanisms was uncovered: grain rotation and grain coalescence dominate at nanocrystalline grain sizes, whereas stress-coupled GB migration prevails at ultrafine grain sizes. In addition, detwinning of the preexisting deformation twins was observed during HPT of the cryomilled Cu powders. The mechanism of detwinning for deformation twins was proposed to be similar to that for growth twins.     

A numerical examination of shear banding and simple shear non-coaxial flow rules

Strain localisation and shear band formation is frequently observed during the handling and flow of dense phase particulate materials. However, a complete understanding of how shear bands form and what happens inside shear bands is still lacking. In order to address this problem, discrete particle simulations have been carried out to examine the detailed processes that occur at the grain scale associated with the initiation and development of shear bands. To reliably identify the continuum model applicable within a shear band is difficult due to the small number of particles/contacts involved. However, it is normally accepted that the mode of deformation within a shear band is one of simple shear. Consequently, simple shear simulations have been performed in order to determine the evolution of the stress tensor, dilation rate, and the principal directions of stress and strain-rate. It is demonstrated that the corresponding non-coaxial flow rule is equivalent to that suggested by Tatsuoka et al. (Géotechnique 38 148 (1988)). Furthermore, at fully developed flow when there is no further change in volume, the stress and strain-rate directions are coaxial and the flow rule is that proposed by Hill (The Mathematical Theory of Plasticity (Oxford University Press, 1950) p. 294).     

Microscopical study of the formation of adiabatic shear bands in 4340 steel during dynamic loading

In this study, optical microscopy, scanning electron microscopy, transmission electron microscopy, X-ray diffraction and electron probe microanalyser were used to analyse the changes in microstructure of AISI 4340 steel specimens caused by impact at high strain rates and large strains. The structures of the steel prior to dynamic deformation and after dynamic deformation were examined to understand on a microscale level, the mechanism of formation of adiabatic shear bands (ASBs). The study also includes the structural changes that occur during post-deformation annealing processes which may relate to understanding of the mechanism of formation of ASBs. Prior to deformation, the tempered steel specimens consisted of lenticular laths of α-ferrite with precipitated platelet and spherical M₃C carbides. After impact, the structure inside the shear band was characterized by refined and recrystallized grains immersed in dense dislocation structures. In addition, residual carbide particles were observed inside the shear bands due to deformation induced carbide dissolution. Regions away from the shear bands developed ‘knitted’ dislocation walls, evolving gradually into sub-boundaries and highly misoriented grain boundaries at increasing strains, leading to grain refinement of the ferrite. After impact, annealing the shear bands at 350?°C resulted in an increase in hardness regardless of the heat treatment before impact, amount of deformation and the time of annealing. This is because of the occurrence of extensive reprecipitation of dissolved carbides that existed in the steel structure prior to deformation. It is concluded that dynamic recovery/recrystallization, development of dislocation structures and carbide dissolution all contribute simultaneously to the formation of ASBs in quench-hardened steels.     

Study of stress localisation in polycrystalline grains using self-consistent modelling and neutron diffraction

The time-of-flight neutron diffraction technique and the elastoplastic self-consistent model were used to study the behaviour of single and multi-phase materials. Critical resolved shear stresses and hardening parameters in austenitic and austenitic–ferritic steels were found by analysing the evolution of the lattice strains measured during tensile tests. Special attention was paid to the changes of the grain stresses occurring due to transition from elastic to plastic deformation. Using a new method of data analysis, the variation of the stress localisation tensor as a function of macrostress was measured. The experimental results were successfully compared with model predictions for both phases of the duplex steel and also for the austenitic sample.     

Deformation of micron-sized aluminium bi-crystal pillars

The deformation of micron-sized single-crystals is jumpy and stochastic, and this may pose potential formability and reliability problems if components for future micro-machines are to be made from small metal volumes. In this work, micron-sized bi-crystal pillars were fabricated by focussed ion-beam milling from grain-boundary regions in coarse-grained polycrystalline aluminium. Each bi-crystal pillar contained a grain boundary intersecting its top surface, and was subjected to compression using a flat-ended nanoindenter tip. Their deformation was found to have smaller strain bursts, fewer periods of strain hardening at elastic-like rates, as well as greater work-hardening rate and flow stress, than single-crystal pillars of similar sizes. Transmission electron microscopy revealed severe dislocation accumulation in the deformed bi-crystal pillars, whereas the residual dislocation density remained low in single-crystal micro-pillars of similar dimensions after deformation to comparable strains. The results suggest that a grain boundary inside a micro-specimen can trap dislocations inside the specimen, leading to a significant rise in the strain-hardening rate as well as to smoother deformation.     

Effect of cyclic stresses on the microstructures of hexagonal close packed metals

Slip band extrusions are formed in cadmium, magnesium and titanium, but not in zinc. The extrusions form preferentially in untwinned crystals. Filamentary growths occur at {10¯12} and {11¯21} twin interfaces during cyclic twinning.Possible dislocation interactions at these twin interfaces are described. The dislocation debris produced during cyclic strain in the slip bands and by cyclic twinning is shown to be similar and composed of a high density of dipole loops. It is therefore concluded that the occurrence and distribution of slip band extrusions in metals and the formation of twin boundary filamentary growths can be accounted for by a model based upon the glide of interstitial type dipole loops. Vacancy type loops will then cause crack nucleation in slip bands and deformation twin boundary regions.Twin boundary debris can also cause the observed fragmentation of twins by acting as a barrier to twin boundary movement.The author is grateful to Dr. A. G. Crocker, University of Surrey, for many discussions on the twinning mode in h.c.p. metals and to P. J. E. Forsyth for his interest and encouragement. The paper is published by permission of the Controller, H. M. Stationery Office. Crown copyright is reserved.     

Grain Growth During Superplastic Deformation

Significant grain growth occurring during superplastic deformation is related to the micro-mechanism of superplastic flow. Observations performed on the deformed surface of superplastically deformed tensile and shear Pb-62%Sn samples and bi-axially formed AA7475 samples directly indicate that cooperative grain boundary sliding, i.e. sliding of grain groups, is accompanied by cooperative grain boundary migration that can result in an enhanced grain growth. Such a long range correlation in migration of sliding grain boundaries is related to movement of grain boundary dislocations having a step associated with its core. Observed correlation between grain size and strain measured in different regions of a superplastically formed Ti-alloy part and alignment of grain boundaries along shear surfaces support coupling of grain boundary sliding and migration. A model of grain growth considering climb of cellular dislocations, topological defects in a grain array, has been expanded to incorporate gliding and mixed cellular dislocations.