Papers by Author: Małgorzata Lewandowska

Abstract: Ti-6Al-4V alloy was heated to above the β phase transformation temperature with two different cooling speeds: air cooling and furnace cooling, in order to generate a full thin lamellar structure and a fully coarse lamellar structure, respectively. Then the alloy in two heat-treated conditions was processed at room temperature up to 10 turns by high-pressure torsion (HPT) processing. Investigations were carried out to study the effect of the different initial lamellar plate thicknesses on the microstructure development during HPT processing, and the corresponding superplastic behaviour at the selected low testing temperatures of 773 - 923 K.

Abstract: In this work, an attempt has been made to improve the mechanical strength of 6063 aluminium alloy and thus its lightness via combination of severe plastic deformation (grain size refinement) and heat treatment (precipitation hardening). 6063 aluminium alloy was chosen as the best material for lightweight structures, where mass reduction is important, because of its high extrudability. Samples were hydrostatically extruded (HE) in supersaturated condition and subsequently subjected to an aging process. HE brings about significant grain size refinement well below 1 micron. The influence of aging parameters such as time and temperature on mechanical properties evolution of extruded material was determined. The microstructure of ultrafine grained (UFG) alloy was investigated using transmission electron microscopy. The average grain diameter and grain boundary misorientation angles (using Kikuchi lines) were measured. Mechanical properties were examined in microhardness and tensile tests. The results have shown that it is possible to combine grain boundary and precipitation strengthening and obtain ultrahigh strength in 6xxx series alloys. Additionally, heat treatment of UFG samples causes an increase in ductility measured in tensile tests, which is rather poor in severely deformed materials. To prove advantages of UFG aged samples for lightweight applications, finite element modelling was performed to compare the mass of chair elements made of coarse and ultrafine grained material. Simulations were made for the same stresses applied. It has been shown that if the chair was made of UFG aluminium alloy the mass reduction would be approximately 30 %.

Abstract: Grain size refinement is an efficient way to improve mechanical strength and thus make light metals even lighter in terms of specific strength. However, the strength improvement is at the expense of ductility. Therefore, a better understanding of microstructural factors influencing both parameters is of prime importance for further development of ultrafine grained materials. In this work, we report results obtained for 5483 aluminium alloy which was subjected to several severe plastic deformation (SPD) methods, i.e. equal channel angular pressing (ECAP), Hydrostatic Extrusion (HE) and the combination of the two. Detailed microstructural analysis revealed significant difference in the grain size and grain boundary characteristics between samples obtained following different routes. It was found that although the grain size is a prime microstructural parameter determining mechanical strength, second order factors such as grain size distribution and distribution of grain boundary misorientation angles also play a significant role.

Abstract: In the present study, SPD processing was combined with annealing in order to obtain synergic effect of grain size refinement and precipitate strengthening. Samples of 7475 alloy were solution heat treated, water quenched and then subjected to hydrostatic extrusion with a total true strain of about 4. Hydrostatic extrusion resulted in a significant grain refinement from 70 mm to about 70 nm. The samples were subsequently annealed at temperatures inducing the formation of nano-precipitates. The investigations of the structure and mechanical properties of the samples subjected to SPD and annealing revealed different precipitation path in micro- and nano-grained samples. Also, it was found that the combination of HE processing and low temperature annealing results in the formation of nano-precipitates in nano-grained structures which effectively strengthen nano-aluminium alloy.

Abstract: The aim of the present work was to compare microstructures and mechanical properties of nano-Al alloys fabricated by two different methods: (i) SPD induced grain refinement, (ii) plastic consolidation of nano-powders or nano-crystalline ribbons. SPD grain refinement has been implemented by hydrostatic extrusion, HE. The ribbons were rapidly solidified using a melt spinning methods. Plastic consolidation of powder and ribbons was conducted by warm extrusion. The results of the studies show that by applying various fabrication routes for a given chemical composition, diverse nano-structures can be obtained, which differ in terms of grain size and shape, grain boundary character and dislocation density. As a result, the alloys also differ significantly in the mechanical properties. The findings are discussed in terms of the possibilities for optimizing properties of the bulk-nano-metals.

Abstract: In the present work, an extensive research program has been undertaken to characterise a wide spectrum of properties of nano-metals. In particular, the effect of grain refinement on such properties as fatigue, corrosion and wear resistance, conductivity and thermal stability has been studied for various nano-metals (aluminium, copper and iron alloys). The results have revealed that nano-grain refinement also improves physical properties of single phase metals. A disadvantageous effect of large (micron sized) particles, which do not undergo refinement during the processing, has been also recognized.

Abstract: Nano-structured metals have attracted growing research interest, which has brought about the development of methods for their fabrication. A number of fabrication methods involve severe plastic deformation, SPD, and involve refinement of the coarse-grained structures to grain sizes on a nanometre scale. Such grain refinement is accompanied by a significant improvement in mechanical strength. The improved properties of the nano-structured metals open up perspectives for their application in innovative industries such as aerospace, surface transport and biomedical implant manufacturing. The advantage of using nano-structured light metals is possible weight reduction of manufactured components. In the case of automotive parts, this may contribute to a reduction in CO2 emissions – one of the most important global challenges – due to the significantly higher strength of nano-structured metals and alloys compared to their microcrystalline counterparts. Nano-structured metals also exhibit high strain rate superplasticity at relatively low temperatures. This offers fast processing of materials, whose superplastic forming would be restricted otherwise. Finally, nano-structured metals also possess improved functional properties such as wear and corrosion resistance, which can broaden the range of applications of engineering metals and alloys even further. This paper reviews recent progress in the development of light nano-engineered metals and alloys. In particular, interest is concentrated on the metals and alloys processed by SPD methods. Conclusions are drawn with regard to future development of light materials for application in transport.

Abstract: Ceramic – polymer composites based on acrylic (bis–GMA) and urethane – methacrylate (UM) resins with a 60 % total volume fraction of filler consisting of micro particles of glass and nano-particles of silica were fabricated. The nano-silica contents were: 0, 10, 20 vol. %. The composite samples were subjected to wear tests using an occlusion simulator tester which applies reciprocating movement and cyclic loading on the test material. This method of testing provides some similarity to the masticatory pattern occurring in the mouth during eating. The enamel of a human tooth was used as a counter-sample. The coefficient of friction was determined and the wear resistance of the composite samples containing the various nano-silica contents was established. In addition, the relative influence of the composite composition on the rate of wear of the human tooth enamel was estimated. The results of the study indicate that the addition of nano-silica significantly improves the wear resistance of the ceramic – polymer composites and reduces the wear of enamel. It was found that the addition of nano-silica has no influence on the coefficient of friction. It was also established that composites based on UM resin show better wear resistance than those based on a mixture of bis-GMA and TEGDMA resin.

Abstract: Thermal management materials frequently have multi-phase composite character with complex architecture of the constituents. As a result, design rules are needed which can be used in selection of the phases and optimizing their volume fractions. The study shows that such are provided by finite element modeling of these composites. This is demonstrated for a diamond-SiC-Si-(Al) composites, which have been optimized in terms of the volume fraction of SiC, contact area between the components and presence of open porosity.

Abstract: Samples of 316LVM stainless steels were hydrostatically extruded in a multi-step process to a total true strain of 1,84 and subsequently annealed at different temperatures. The structural changes occurring as a result of HE and annealing were observed using a transmission electron microscope. The microhardness of the samples was measured using a load of 200g. The results show that hydrostatic extrusion results in a uniform microstructure characterized by a high density of nano-twins. Subsequent annealing at 600°C produces a partial transformation to a nano structure of average grain size 54 nm. At an annealing temperature of 700°C a fullyrecrystallized uniform microstructure consisting of 68 nm diameter nano-grains was formed. It should be noted that 700°C is much lower than that required to recrystallize a micro-grained alloy of the same composition. The microstructural changes which occurred during annealing have a significant effect on the mechanical properties. The microhardness after HE increased following annealing at 500°C. However, annealing at 800°C resulted in a drop in microhardness, indicating the occurrence of grain growth.