Papers by Author: Tatsuo Sato

Abstract: The effect of PFZ and grain boundary precipitates formed in aging processes on the macroscopic mechanical properties in Al-Zn-Mg(-Ag) alloys were evaluated using TEM, SEM, tensile test and nanoindentation. Decreases in width of PFZ and smaller size of grain boundary precipitates aging at lower temperatures and/or the addition of Ag processes improved the tensile properties, and the presence of PFZ was found to be harmful to the fracture. Nanoindentation hardness results clarified that the hardness within PFZ is smaller than that in grain interiors, indicating that, in the alloy with large width of PFZ, preferential deformation occurs within PFZ in the initial stage of deformation, and this causes lower elongation regardless of the same level of proof stress and the same sizes of grain boundary precipitates. From the quantitative correlation between precipitate microstructures in the vicinity of grain boundaries, mechanical properties and fracture morphologies, the deformation process of the alloys is considered to divided by three types; i.e. in case of the alloys with the small width of PFZ and the small size of grain boundary precipitates, in case of the alloys with the large width of PFZ and the small size of grain boundary precipitates and in case of the alloys with the large width of PFZ and the large size of grain boundary precipitates.

Abstract: The atomistic behaviors of microalloying elements during phase decomposition of Al- Cu-Mg, Al-Zn-Mg and Al-Mg-Si alloys have been systematically predicted in terms of two-body interaction energies between solutes and/or vacancies. The utilized first-principles calculation based on generalized gradient approximation (GGA) and full-potential Korringa-Kohn-Rostoker (FPKKR) Green’s function method accurately estimated such fundamental energies in good agreement with experimentally reported behaviors: e.g. vacancy-trapping model, vacancy-sink model and nanocluster assist processing. The proposed interaction energy maps (IE maps), in which the estimated interaction energies are plotted along the rows of the periodic table, are quite useful for designing new aluminum alloys with microalloying elements.

Abstract: The purpose of this study is to identify the crystal structure of metastable phase in Ag added Al-Mg-Si alloy to compare the formation of β’-phases in Al-Mg-Si alloys without Ag, using images of high resolution transmission electron microscope (HRTEM), selected area electron diffraction (SAED) patterns and an energy dispersive X-ray spectroscopy (EDS). The result of SAED patterns and HRTEM images have been simulated and compared with images then SAED patterns obtained from actual precipitates. SAED patterns and HRTEM images obtained from metastable phase in the Ag added Al-Mg-Si alloy showed similar to those of β’-phase in Al-Mg-Si alloy without Ag and the lattice spacings changed because of the effect of Ag.

Abstract: It is well known that Ag additional Al-1.0mass%Mg2Si-excess0.4mass%Si alloy (ex. Si-Ag alloy) has higher hardness and elongation than those of Al-1.0mass%Mg2Si-excess 0.4mass%Si alloy (ex. Si alloy). However, precipitation sequence of ex. Si-Ag alloy is not clear yet. In this work, precipitation sequence of ex. Si-Ag alloy has been investigated using high resolution transmission electron microscopy and X-ray energy dispersive spectroscopy. Precipitates were classified into several kinds by HRTEM images and SAED patterns, and relative frequencies of precipitates were also investigated. Its precipitation sequence was compared with that of ex. Si alloy. Type-A, Type-B and Type-C precipitates as special metastable phase in excess Si type Al-Mg-Si alloy, has been observed in ex. Si-Ag alloy, but β’ phase increased and Type-A and Type-B precipitate decreased in this study. Type-A precipitate was found at only grain boundary.

Abstract: The effectiveness of microalloying addition and two-step aging on the mechanical properties of the Al-Zn-Mg alloy has been investigated using TEM, tensile test and nanoindentation. By decreasing width of PFZ and size of grain boundary precipitates through the addition of (Ag+Sn) or two-step aging process, tensile properties of Al-Zn-Mg alloys are markedly improved. The elongation was quantitatively related to the three microstructural factors; i.e. the width of PFZ, size of grain boundary precipitates and the level of proof stress, to predict ductility of the alloys with known microstructural factors. The fracture mode change is reasonably in terms of the hardness difference between grain interiors and PFZ region by a noindentation technique.

Abstract: Creep rupture tests were performed for a die-cast Mg-Al-Ca alloy AX52 (X representing calcium) at 29 kinds of creep conditions in the temperature range between 423 and 498 K. The creep curve for the alloy is characterized by a minimum in the creep rate followed by an accelerating stage. The minimum creep rate (ε& m) and the creep rupture life (trup) follow the phenomenological Monkman-Grant relationship; trup = C0 /ε& m m. It is found for the AX52 die-cast alloy that the exponent m is unity and the constant C0 is 2.0 x 10-2, independent of creep testing temperature. The values of m and C0 are compared with those for another die-cast magnesium alloys. The value m=1 is generally detected for die-cast magnesium alloys. On the contrary, the value of C0 sensitively depends on alloy composition, which is reduced with increasing the concentration of alloying elements such as Al, Zn and Ca.

Abstract: The crystal structure of metastable phase in Ag added Al-Mg-Si alloy was investigated by comparing the β’-phases in Al-Mg-Si alloy without Ag, using images of high resolution transmission electron microscope (HRTEM), selected area electron diffraction patterns (SADPs) and an energy dispersive X-ray spectroscopy (EDS). SADPs and HRTEM images obtained from metastable phase in the Ag added Al-Mg-Si alloy showed similar to those of β’-phase in Al-Mg-Si alloy without Ag and had different lattice spacings because of the effect of Ag. According to our careful analysis on obtained HRTEM images and SADPs, it includes more complicated crystal lattice of distorted hexagons.

Abstract: In this study, asymmetric warm rolling (AWR) has been applied to improve the formability of bake-hardenable Al-3mass%Mg-1mass%Cu-(Ag) alloy sheets. The T4 sheets by the AWR are superior to those by conventional rolling (CR) in Lankford value and drawability. This improvement is caused by a change in the recrystallization texture to have a predominant orientation close to {111}//ND. The unusual texture for recrystallized aluminum alloy sheets is due to the shear deformation introduced during AWR. The Al-Mg-Cu alloy sheets by AWR have been confirmed to possess combined bake-hardenability and the improved formability. However, the bake-hardening response of the Al-Mg-Cu alloy by AWR is slightly inferior to that of the identical alloy by CR.

Abstract: The purpose of this study is identity the crystal structure of metastable phase in Ag added Al-Mg-Si alloy by comparing the β’-phases in Al-Mg-Si alloy without Ag, using images of high resolution transmission electron microscope (HRTEM), selected area electron diffraction patterns (SADPs) and an energy dispersive X-ray spectroscopy (EDS). The result of SADPs and HRTEM images have been simulated and compared with images and SADPs obtained from actual precipitates. SADPs and HRTEM images obtained from metastable phase in the Ag added Al-Mg-Si alloy showed similar to those of β’-phase in Al-Mg-Si alloy without Ag and had different lattice spacings because of the effect of Ag.