Papers by Author: Katsuaki Nakamura

Abstract: Severe plastic deformation (SPD) makes it possible to refine grain size in many metallic materials. Recently, we have developed a new SPD process designated the severe torsion straining process (STSP). This process requires no die but one side of a rod is rotated with respect to the other while producing a local heated zone in the rod and cooling both sides of the heated zone. Torsion strain is then introduced in the local heated zone. The STSP can be a continuous process because the rod is moved in the longitudinal direction while introducing torsion strain through the rotation. For grain refinement using the STSP, various factors may affect, which are the rotation speed, moving speed, straining temperature, cooling rate and diameter of the rod. In this study, the STSP is applied to grain refinement of an A5056 Al-Mg commercial alloy and the factors affecting the grain refinement are optimized. STSP was conducted at a temperature in the range from 573K to 723K. Microstructure was observed by optical microscopy, scanning electron microscopy with an orientation imaging system, and transmission electron microscopy. Microscopy observations revealed that the grain size was reduced to ~0.9 μm, when STSP was conducted at 573K with a rotation speed of 10 rpm and moving speed of 50 mm/min. There is a critical ratio of rotation speed to moving speed above which the rod breaks. The grain size tends to be finer as the straining temperature is lower, the cooling rate is faster and the ratio of rotation speed to moving speed is closer to the critical value.

Abstract: Grain refinement is attempted using severe plastic deformation (SPD) through the severe torsion straining process (STSP) which we have developed recently. The STSP is a continuous process for grain refinement without requirement of any die. In this study, an AZ61 Mg alloy was subjected to STSP at a temperature of 573 K with a rotation speed of 10 rpm and a moving speed of 200 mm/min. With this process, an initial grain size of ~20 μm was reduced to ~2~3 μm. Room temperature compression tests revealed that there were no cracks after 15% of compression for the STSP sample whereas fracture occurred for a conventionally extruded sample. For compression tests at 473 K, no cracks occurred in the STSP samples after 80% compression but compression was feasible without cracking only up to 20% for an extruded sample. It is shown that the STSP can be useful for grain refinement and ductility improvement of the AZ61 Mg alloy.

Abstract: High pressure torsion (HPT) is a well-known procedure to impart severe plastic deformation (SPD) into metallic materials. It was reported that HPT produces grain sizes finer than those using other SPD processes such as equal-channel angular pressing (ECAP). However, the application of HPT has been restricted to thin disk samples. In this study, an HPT process was developed for use with bulk samples. This process is designated as Bulk-HPT for comparison with conventional Disk-HPT. Cylindrical samples of an Al-3%Mg-0.2%Sc alloy having dimensions of 10 mm in diameter and 8.6 mm in height were prepared for Bulk-HPT. The samples were strained under a pressure of 1 GPa for 2 turns at room temperature. Microstructural observations revealed that the samples contained regions having a grain size of ~130 nm. Tensile testing showed a superplastic ductility ~480 % at 673 K with an initial strain rate of 3.3x10-2 s-1.

Abstract: This study presents a new rapid continuous process for grain refinement in metallic materials through severe plastic deformation (SPD). The new process, designated in this study the severe torsion straining process (STSP), is applicable to a wide range of alloys based on aluminum, magnesium and copper including carbon steel. This process consists of producing a local heated zone in a rod and cooling both sides of the heated zone by spray water while rotating one end with the other. Thus, torsion strain is introduced in the local heated zone. The STSP can be continuous because the straining is achieved while the rod is shifted along the longitudinal axis of the rod. Furthermore, the process requires no die, suggesting a potential for commercialization of grain refinement through SPD. In this study, STSP was applied to an Al-Mg alloy and a Mg-Al-Zn alloy. It is shown that STSP is effective for both alloys so that the grain size is reduced to ~1.5 μm for the Al alloy and ~0.9 μm for the Mg alloy. Tensile testing showed that the strength is increased with a minimal decrease in uniform elongation. There is a critical ratio between rotation speed and moving speed, which defines the feasibility of STSP operation without breaking the rod. The grain size tends to be lowered as the ratio is close to the critical value.