ABSTRACT
Aluminum alloys are one of the most common structural materials. To improve the mechanical properties, an alloy of the Al-Zn-Mg-Ca-Fe system was proposed. In this alloy, when Fe and Ca are added, compact particles of the Al10CaFe2 compound are formed, which significantly reduces the negative effect of Fe on the mechanical properties. Because of the high solidification rate (about 600 K/s) during cylindrical ingot (~33 mm) production, the electromagnetic casting method (ECM) makes it possible to obtain a highly dispersed structure in the cast state. The size of the dendritic cell is ~7 µm, while the entire amount of Fe is bound into eutectic inclusions of the Al10CaFe2 phase with an average size of less than 3 µm. In this study, the effect of radial shear rolling (RSR) on the formation of the structure and hardening of the Al-8%Zn-3.3%Mg-0.8%Ca-1.1%Fe alloy obtained by EMC was studied. Computer simulation of the RSR process made it possible to analyze the temperature and stress-strain state of the alloy and to select the optimal rolling modes. It was shown that the flow features during RSR and the severe shear strains near the surface of the rod (10 mm) provided a refining and decrease in the size of the initial Fe-containing particles.
ABSTRACT
The comprehensive analysis of temperature influence on the strain-speed parameters of radial-shear rolling of Al-Zn-Mg-Ni-Fe alloy including the investigation of rheological properties, FEM simulation, and in-depth analytical interpretation of results was carried out. The rolling temperature has significant effect on the kinematic of metal forming, speed parameters, configuration, and length of trajectories. With the decrease in temperature, the speed of metal movement reduces, and this is the same for different components. The greatest decrease is noted for the axial speed component. In general, according to the nature of effect on the strain kinematic state, a temperature reduction of 100 °C (from 500 to 400 °C) acts similarly to a decrease in feed angle of about 4° and, in particular, increases the rolling time, nonuniformity of deformation, tightening, and temperature effect of deformation heating.
