Papers by Author: Matthias Hockauf

Abstract: Future applications of ultrafine-grained, high performance materials produced by equal-channel angular pressing (ECAP) will most likely require processing on an industrial scale. There is a need for detailed microstructural and mechanical characterisation of large-scale, ECAP-processed billets. In the present study, we examine the microstructure and mechanical properties as a function of location and orientation within large (50 x 50 x 300 mm³) billets of an Al 6060 alloy produced by ECAP (90° channel angle) with different magnitudes of backpressure. The internal deformation is analysed using a grid-line method on split billets. Hardness is recorded in longitudinal and cross-sectional planes. In order to further characterise the local, post-ECAP mechanical properties, tensile tests in different layers are performed. Moreover, low voltage scanning transmission electron microscopy observations highlight relevant microstructural features. We find that the homogeneity and anisotropy of mechanical properties within the billets depend significantly on the geometry of the shear zone. We demonstrate that deformation gradients can be reduced considerably by increasing the backpressure: The opening-angle of the fan-shaped shear zone is reduced from ψ ≈ 20 ° to ψ ≈ 7 ° when the backpressure is increased from 0 to 150 MPa. Backpressures of 150 MPa result in excellent homogeneity, with a relative variation of tensile mechanical properties of less than 7 %. Our investigation demonstrates that ECAP is suitable for processing homogenous, high performance materials on a large scale, paving the way for advanced industrial applications.

Abstract: In the present work, the near-threshold fatigue crack propagation (FCP) at different load ratios is studied for an aluminium alloy processed by equal-channel angular pressing (ECAP). The conditions under investigation represent different stages of microstructural refinement as well as a ductility-optimized condition with superior crack growth properties, obtained by a combination of ECAP and aging. The results show a strong dependency of the threshold and its load ratio sensitivity on the grain size and grain size distribution. These observations can be rationalized on the basis of crack path tortuosity and the contribution of (roughness-induced) crack closure. Moreover, the experimental data is evaluated using the two-parametric concept of Vasudevan and Sadananda, which employs two necessary minimum conditions for crack growth, namely a critical cyclic K*th, and a critical maximum stress intensity K*max. The application of this concept shows a strong interaction of both parameters for all ECAP-processed conditions, where the ductility-optimized condition reveals superior FCP properties compared to the “as-processed” conditions.

Abstract: Equal-channel angular pressing (ECAP) was applied to polycrystalline NiAl at temperatures around the brittle-to-ductile transition temperature (BDTT). NiAl rods encapsulated in a steel jacket were ECAP-processed in a die with a channel angle of 120°. The microstructure and texture were characterized by electron backscatter diffraction with a scanning electron microscope. The volume fraction of the texture components typical for simple shear in the intersection plane of the channels changes in the range of the BDTT.

Abstract: The corrosion behaviour of the aluminium alloy, AA6082, processed by equal-channel angular pressing (ECAP) after different passes (route E, room temperature) was studied in comparison to the coarse-grained counterpart. The results of the electrochemical investigations (cyclovoltammetry; electrochemical impedance spectroscopy, EIS) are presented in correlation with the microstructure before and after the corrosion examinations. Both, chemical (precipitations, phases) and physical (dislocations, high-angle grain boundaries, grain size, low-angle grain boundaries) inhomogeneities characterize the microstructure of this commercially used Al-Mg-Si alloy. Results indicate an improved resistance against pitting of the ECAP material expressed by a reduced pitting density of up to 50 % and lower pit depths. EIS measurements and microstructural examinations (scanning electron microscopy, transmission electron microscopy, 3D topography measurement) confirm that ECAP modifies the number, size and distribution of these inhomogeneities, which leads to a more favourable corrosion behaviour.

Abstract: Crack growth in AA6060 after two and eight equal-channel angular extrusions (ECAE), showing a bimodal microstructure and a homogenous ultrafine-grained microstructure, respectively, are compared to the coarse grained counterpart. Furthermore, an optimized condition, obtained by combining one ECA-extrusion and a subsequent short aging treatment is included. Fatigue crack growth behaviour in the near-threshold regime and the region of stable crack growth is investigated and related to microstructural features such as grain size, grain size distribution, grain boundary characteristics and ductility. Micrographs of crack propagation surfaces reveal information on crack propagation features such as crack path deflection and give an insight to the underlying microstructure. Instrumented Charpy impact tests are performed to investigate crack initiation and propagation under impact conditions. Due to the recovery of ductility during the post-ECAE heat treatment, the optimized condition shows improved fatigue crack properties and higher energy consumption in Charpy impact tests, when compared to the as-processed conditions without heat treatment.

Abstract: The effect of equal-channel angular extrusion (ECAE) on mechanical properties of an AA2017 produced by powder metallurgy is investigated. Special attention is given to the influence of heat treatment, processing temperature and backpressure on the workability for achieving high strength and moderate ductility. This is of special interest, since it is often reported that Al-Cu alloys have low ductility and therefore are prone to cracking during severe plastic deformation. It is shown that ECAE at high temperatures (>220°C) does not necessitate backpressure to ensure homogeneous deformation but leads to a significant sacrifice in strength due to in-situ precipitation. Thus, most of the extrusions are done at considerably low temperatures. Performing room temperature-extrusion is most effective in achieving high strengths but also requires high backpressures. Due to severe strain hardening during processing, the strength increase is combined with a reduction in ductility. Recently it was reported that a post-ECAE aging of pre-ECAE solution treated material is effective in enhancing the ductility of aluminium alloys. This approach was successfully transferred to the current alloy. A high-temperature, short-time aging after only one extrusion, for example, doubles the failure strain to a value of ~13%. Compared to the naturally aged condition with coarse grains that serves as reference (T4), an increase of 15 % in yield stress (YS) was obtained while retaining the ultimate tensile stress (UTS). Another effective approach is the combination of a pre-ECAE solution treatment with subsequent under-aging prior to ECAE. It is shown that performing ECAE at medium temperatures (160-180°C) enables a better workability and additionally gives higher strengths and better ductility compared to the processing in the water quenched condition. A remarkable YS of 530 MPa and an UTS of 580 MPa combined with a moderate failure strain of 11.6 % were achieved.

Abstract: A tungsten heavy alloy (92%W, Ni-Co matrix) is subjected to severe plastic deformation (SPD) by high pressure torsion (HPT) at room temperature up to equivalent strains of 0.7, 5.3, 10.7 and 14.3. The microstructure and the mechanical properties are investigated by cylindrical compression samples at quasi-static and dynamic loading. The harder spherical W particles are homogeneously deformed within the softer matrix, becoming ellipsoidal at medium strains and banded at high strains without shear localization or fracture. Results of quasi-static loading show that the strength is approaching a limiting value at strains of ~10. At this strain for the matrix a grain size of ~80 nm and for W a cell size of ~250 nm was observed, suggesting strain concentration on the matrix. The initial yield stress of 945 MPa for the coarse-grained condition is increased thereby to an ultimate value of 3500 MPa, while a peak stress of ~3600 MPa is reached. Such remarkably strength has never been reported before for pure W or W-based composites. The strain hardening capacity as well as the strain rate sensitivity is reduced drastically, promoting the early formation of (adiabatic) shear bands.