Materials Science Forum Vols. 503-504

Abstract: Recently nanocrystalline Al-Fe alloys produced by a vapor quench method have been reported. These alloys are supersaturated solid solution and exhibit high strength with good ductility. It is postulated that the high strength of the Al-Fe alloys could be achieved by both the nano-grained structures and the solid solution strengthening. The contribution to the yield strength due to both the grain size strengthening and the solid solution strengthening were analyzed from the experimental data. Then the contribution to the yield strength due to the solid solution strengthening was estimated from the misfit strain calculated from the first principles in order to compare with analytical results estimated from the experimental data.

Abstract: In this study, bottom-up type powder processing and top-down type SPD (severe plastic deformation) approaches were combined in order to achieve both full density and grain refinement of metallic powders with least grain growth, which was considered as a bottle neck of the bottom-up method using the conventional powder metallurgy of compaction and sintering. ECAP (Equal channel angular pressing), one of the most promising method in SPD, was used for the powder consolidation. In the ECAP process of not only solid but also powder metals, knowledge of the density as well as internal stress, strain and strain rate distribution is important for understanding the process. We investigated the consolidation, plastic deformation and microstructure evolution behavior of the metallic powders during ECAP using experimental and theoretical methods. Almost independent behavior of powder densification in the entry channel and shear deformation in the main deformation zone was found by the finite element method in conjunction with a pressure dependent material yield model. It was found that high mechanical strength could be achieved effectively as a result of the well bonded powder contact surface during ECAP process of gas atomized Al-Si powders. The SPD processing of powders is a viable method to achieve both fully density and nanostructured materials.

Abstract: An SUS316L and a Ti-6Al-4V alloy powders are treated by Mechanical Milling (MM) process, which is one of SPD processes, and then sintered by Hot Roll Sintering (HRS) process. The HRS process consolidates powder by hot rolling of an evacuated metal pipe filled with the powder at elevated temperatures. Those MM powders have a heavy deformed microstructure at the surface region and have a work hardened microstructure in the core region of the powder. In the surface region, a nano grain structure forms after the MM treatment in both materials. In case of the SUS316L powder, such a nano grain structure consists of an equiaxed nano ferrite (􀁄) grains which has transformed from nano austenite (􀁊) grains. Volume fraction of the 􀁄 phase decreases with distance from the surface of powder. During HRS the (􀁄 + 􀁊) nano-duplex structure changes to (sigma (􀁖) + 􀁊) nano-duplex structure by transformation of the 􀁄 to the 􀁖 phase. Thus, the SUS316L HRS material consists of a hybrid structure. That is, a (􀁖 + 􀁊) nano-duplex structure at the powder shell region, and a work hardened 􀁊 structure in the powder core region. In case of the Ti-6Al-4V MM powder, though no remarkable transformation occurs, a heavy deformed shell and work hardened core hybrid structure is also produced in the powder. By HRS the Ti-6Al-4V MM powder demonstrates a hybrid structure consists of an equiaxed nano grain structure and a coarse martensite structure. These two HRS materials indicate superior mechanical properties. Mechanical properties are improved by the HRS process. The proof stress and tensile strength in the SUS316L HRS material are x3.8 and x2.1 of the SUS316L conventional material, respectively. In the Ti-6Al-4V HRS material, they are x1.7 and x1.5 compared to the Ti-6Al-4V conventional material.

Abstract: Pure aluminium and titanium powders were successfully synthesised into bulk materials using equal channel angular (ECA) consolidation. Powders were used directly without the need to cold-compact them into green bodies. The processing temperatures were significantly lower than the usual sintering temperatures for aluminium and titanium. Fully dense bulk samples were achieved after one pass of ECA deformation through a 90 degree die. Mechanical properties of the as-ECA processed materials were comparable to those of wrought aluminium and titanium through ingot metallurgy. Multiple passes of ECA deformation resulted in refined microstructure and improved mechanical properties. The new process has many advantages over conventional powder sintering and is capable of producing bulk nanomaterials of high integrity.

Abstract: Deformation behavior in the vicinity of grain boundary in Fe-0.4wt%C tempered martensitic steel were studied through in-situ nanoindentation in a TEM. Two types of boundaries were imaged in the dislocated martensitic structure: a low-angle lath boundary and a high-angle block boundary. In the case of a low-angle grain boundary, the dislocations induced by the indenter piled up against the boundary. As the indenter penetrated further, a critical stress appears to have been reached and a high density of dislocations was suddenly emitted on the far side of the grain boundary into the adjacent grain. In the case of the high-angle grain boundary, the numerous dislocations that were produced by the indentation were simply absorbed into the boundary, with no indication of pile-up or the transmission of strain.

Abstract: High purity (99.99%) pure aluminium processed by equal channel angular pressing (ECAP) was examined in terms of the ECAP microstructure inhomogeneity and its creep behaviour. The results indicate that an inhomogeneity of the ECAP microstructure in mesoscopic scale may influence the creep behaviour of the pressed material.

Abstract: The uniformity of grain coarsening throughout the microstructure of a submicron grained particle-containing aluminium alloy has been investigated using high resolution EBSD. The alloy was processed by equal channel angular pressing (ECAP) and low temperature ageing to generate ~0.8 􀁐m diameter grain structure containing a relatively uniform dispersion of nanosized Al3Sc particles. While the initial processing route generated a uniform grain size distribution, the distribution of grain orientations was rather inhomogeneous with certain regions of microstructure containing colonies of grains consisting predominantly of either HAGBs or LAGBs. It was found that, despite the difference in grain boundary character between these regions, the fine particles produced by pre-ageing promote uniform coarsening throughout the microstructure despite the marked differences in boundary character between these regions. An analytical model is outlined which predicts the uniformity of grain coarsening in particle-containing alloys despite the presence of orientation gradients in the microstructure.

Abstract: The available to date experimental results are reviewed with regard to the common aspects and features of monotonic and cyclic stress-strain behavior of various ultra-fine grain materials produced by severe plastic deformation (SPD). Some possible mechanisms of plastic flow and degradation during monotonic and cyclic testing are discussed from the standpoint of initial SPD structure and its evolution upon loading. The role of two strengthening mechanisms – dislocation accumulation and grain reduction - is highlighted. The key importance of grain boundaries for the mechanical behavior, strain localization and fracture of ultra-fine grain metals is argued and the experimental evidence is presented on the significance of grain boundary sliding in their plastic deformation. The results of phenomenological modeling of the monotonic and cyclic response of ultra-fine grain metals are presented in terms of dislocation kinetics and a satisfactory agreement with experimental data is demonstrated.