Grain Structure Evolution in 6013 Aluminum Alloy during High Heat-Input Friction-Stir Welding.

This work was undertaken to evaluate the influence of friction-stir welding (FSW) under a high-heat input condition on microstructural evolution. Given the extreme combination of deformation conditions associated with such an FSW regime (including the highest strain, temperature, and strain rate), it was expected to result in an unusual structural response. For this investigation, a commercial 6013 aluminum alloy was used as a program material, and FSW was conducted at a relatively high spindle rate of 1100 rpm and an extremely low feed rate of 13 mm/min; moreover, a Ti-6Al-4V backing plate was employed to reduce heat loss during welding. It was found that the high-heat-input FSW resulted in the formation of a pronounced fine-grained layer at the upper weld surface. This observation was attributed to the stirring action exerted by the shoulder of the FSW tool. Another important issue was the retardation of continuous recrystallization. This interesting phenomenon was explained in terms of a competition between recrystallization and recovery at high temperatures. Specifically, the activation of recovery should reduce dislocation density and thus retard the development of deformation-induced boundaries.

Strength-Toughness of a Low-Alloy 0.25C Steel Treated by Q&P Processing.

Quenching and partitioning (Q&P) treatments were applied to 0.25C steel to produce the microstructures that exhibit an improved balance of mechanical properties. The simultaneous bainitic transformation and carbon enrichment of retained austenite (RA) during the partitioning stage at 350 °C result in the coexistence of RA islands with irregular shapes embedded in bainitic ferrite and film-like RA in the martensitic matrix. The decomposition of coarse RA islands and the tempering of primary martensite during partitioning is accompanied by a decrease in the dislocation density and the precipitation/growth of η-carbide in the lath interiors of primary martensite. The best combinations of a yield strength above 1200 MPa and an impact toughness of about 100 J were obtained in the steel samples quenched to 210-230 °C and subjected to partitioning at 350 °C for 100-600 s. A detailed analysis of the microstructures and the mechanical properties of the steel subjected to Q&P, water quenching, and isothermal treatment revealed that the ideal strength-toughness combinations could be attributed to the mixture of the tempered lath martensite with finely dispersed and stabilized RA and the particles of η-carbide located in the lath interiors.

Microstructural Aspects of the Fabrication of Al/Al2O3 Composite by Friction Stir Processing.

The purpose of this work was the examination of microstructural evolution during the fabrication of an Al/Al2O3 composite by friction stir processing (FSP). In order to obtain new insight into this process, a longitudinal section of the produced composite was studied, and advanced characterization techniques (including electron backscatter diffraction and microhardness mapping) were applied. It was found that the reinforcing particles rapidly rearranged into the "onion-ring" structure, which was very stable against the subsequent dispersion. Specifically, the remnants of the comparatively coarse-scale particle agglomerations have survived even after 12 FSP passes. Therefore, it was concluded that three or four FSP passes, which are often applied in practice, are not sufficient to provide a homogeneous dispersion of the reinforcing particles. It was also revealed that the gradual distribution of the nanoscale Al2O3 particles throughout the aluminum matrix promoted a subtle reduction in both the portion of high-angle boundaries and the average grain size. These observations were attributed to the particle pinning of grain-boundary migration and dislocation slip.

Effect of Tempforming on Strength and Toughness of Medium-Carbon Low-Alloy Steel.

The effect of tempforming on the strength and fracture toughness of 0.4%C-2%Si-1%Cr-1%Mo-VNb steel was examined. Plate rolling followed by tempering at the same temperature of 600 °C increases yield stress by 25% and the Charpy V-notch impact energy by a factor of ~10. Increasing rolling reduction leads to the reorientation and elongation of grains toward the rolling direction (RD) and the development of a strong {001} <110> (rotated cube) texture component that highly enhances fracture toughness. A lamellar structure with a spacing of 72 nm between boundaries and a lattice dislocation density of ~1015 m-2 evolves after tempforming at 600 °C with a total strain of 1.4. Two types of delamination were found, attributed to crack branching and the propagation of secondary cracks along the rolling plane perpendicular to the propagation direction of the primary crack. Delamination toughness is associated with the nucleation of secondary cracks in RD and their propagation over a large distance. The critical condition for delamination toughness is the propagation of primary cracks by the ductile fracture mechanism and the propagation of secondary cracks by the brittle quasi-cleavage mechanism.

Tailoring of Dissimilar Friction Stir Lap Welding of Aluminum and Titanium.

An approach was proposed to optimize dissimilar friction stir lap welding of aluminum and titanium alloys. The basic concept of the new technique included (i) the plunging of the welding tool solely into the aluminum part (i.e., no direct contact with the titanium side) and (ii) the welding at a relatively high-heat input condition. It was shown that sound welds could be readily produced using an ordinary cost-effective tool, with no tool abrasion and no dispersion of harmful titanium fragments within the aluminum side. Moreover, the intermetallic layer was found to be as narrow as ~0.1 µm, thus giving rise to excellent bond strength between aluminum and titanium. On the other hand, several important shortcomings were also revealed. First of all, the high-heat input condition provided significant microstructural changes in the aluminum part, thereby resulting in essential material softening. Furthermore, the new approach was not feasible in the case of highly alloyed aluminum alloys due to the relatively low rate of self-diffusion in these materials. An essential issue was also a comparatively narrow processing window.

Dissimilar Friction Stir Welding of AA2519 and AA5182.

In this study, the friction-stir welding (FSW) technique was successfully applied for joining of AA2519 to AA5181 alloy. Microstructure and mechanical properties of dissimilar FSW joints were investigated by optical microscopy, microhardness, and tensile testing. The deformation behaviour of the welded joints was elucidated via the digital image correlation technique. After welding, the ultimate tensile strength of joints was ~300 MPa and ductility was ~16%. The microhardness values observed at the stir zone were higher than those in the base material AA5182. The produced welds demonstrate nearly 100% (based on AA5182) joint efficiency.

Thermo-Mechanical Processing as Method Decreasing Delta-Ferrite and Improving the Impact Toughness of the Novel 12% Cr Steels with Low N and High B Contents.

The universal thermo-mechanical processing including the interim long-term annealing together with forging for three 12% Cr martensitic steels with different alloying. This thermo-mechanical processing remarkably increases the impact toughness of these steels in wide temperature ranges and reduces the ductile-brittle transition temperature by 10-20 K. There is a 25 °C impact toughness of all 12% Cr steels subjected to the thermo-mechanical processing exceeds 60 J cm-2. Such an increment in impact toughness is accompanied with the significant changes in the structures of all 12% Cr steels with different alloying. The common feature for all 12% Cr steels subjected to the thermo-mechanical processing is found to be a noticeable decrease in delta-ferrite amount. In the steels containing Ta, the decrease in the mean size of prior austenite grains by 20-26% was revealed. For the 12% Cr steels with ultra-low N content, the thermo-mechanical processing provides the changes in the dispersion of M23C6 carbides and MX carbonitrides.

Regularities of Microstructure Evolution in a Cu-Cr-Zr Alloy during Severe Plastic Deformation.

The effect of severe plastic deformation by the conforming process of equal channel angular extrusion (ECAE-Conform) followed by cold rolling on the microstructures developed in a Cu-0.1Cr-0.1Zr alloy was investigated. Following the ECAE-Conform of 1 to 8 passes (corresponding strains were 0.8 to 6.4) cold rolling to a total strain of 4 was accompanied by substantial grain refinement and strengthening. An average grain size tended to approach 160 nm with an increase in the rolling reduction. An increase in the ECAE-Conform strain promoted the grain refinement during subsequent cold rolling. The fraction of the ultrafine grains with a size of 160 nm after cold rolling to a strain of 4 increased from 0.12 to 0.52 as the number of ECAE-Conform passes increased from 1 to 8. Correspondingly, the yield strength increased above 550 MPa. The strengthening could be expressed by a Hall-Petch type relationship with a grain size strengthening factor of 0.11 MPa m0.5.

Tempforming Strengthening of a Low-Alloy Steel.

Low-alloy structural steels subjected to quenching and tempering to achieve high strength possess a common drawback associated with low-impact toughness at low temperatures. An additional warm rolling, i.e., tempforming, is a promising approach to strengthen the rolled semi-products along with increasing their impact toughness. The effect of tempforming at 823-923 K on the microstructures and the mechanical properties of a low-alloy steel was studied in comparison with ordinary tempering at the same temperatures. The tempformed microstructures consisted of highly flattened grains with a transverse grain size of 245 nm to 360 nm depending on tempering temperature. A decrease in the transverse grain size with a decreasing temperature was accompanied by an increase in the total dislocation density (including sub-boundary dislocations) from 3.3 × 1015 m-2 to 5.9 × 1015 m-2. The steel samples subjected to tempforming exhibited enhanced mechanical properties. The yield strength increased by more than 300 MPa, approaching about 1200-1500 MPa depending on tempforming temperature. Moreover, strengthening by tempforming was accompanied by an increase in the impact toughness, especially inthe low temperature range down to 77 K, where the impact toughness was above 80 J cm-2.

Peculiarities of DRX in a Highly-Alloyed Austenitic Stainless Steel.

The features of discontinuous dynamic recrystallization (DRX) in a highly-alloyed austenitic stainless steel were studied at temperatures of 800 °C to 1100 °C. Hot deformation accompanied by DRX was characterized by an activation energy of 415 kJ/mol. The frequency of the sequential DRX cycles depended on the deformation conditions; and the largest fraction of DRX grains with small grain orientation spread below 1° was observed at a temperature of around 1000 °C and a strain rate of about 10-3 s-1. The following power law relationships were obtained for DRX grain size (DDRX) and dislocation density (ρ) vs. temperature-compensated strain rate (Z) or peak flow stress (σP): DDRX ~ Z-0.25, ρ ~ Z0.1, σP ~ DDRX-0.9, σP ~ ρ1.4. The latter, i.e., σP ~ ρ1.4, was valid in the flow stress range below 300 MPa and changed to σP ~ ρ0.5 on increasing the stress. The obtained dependencies suggest a unique power law function between the dislocation density and the DRX grain size with an exponent of -0.5.

On the Fatigue Performance of Friction-Stir Welded Aluminum Alloys.

This work was undertaken in an attempt to ascertain the generic characteristics of fatigue behavior of friction-stir welded aluminum alloys. To this end, different alloy grades belonging to both the heat-treatable and non-heat-treatable types in both the cast and wrought conditions were studied. The analysis was based on the premise that the fatigue endurance of sound welds (in which internal flaws and surface quality are not the major issues) is governed by residual stress and microstructure. Considering the relatively low magnitude of the residual stresses but drastic grain refinement attributable to friction-stir welding, the fatigue performance at relatively low cyclic stress was deduced to be dictated by the microstructural factor. Accordingly, the fatigue crack typically nucleated in relatively coarse-grained base material zone; thus, the fatigue strength of the welded joints was comparable to that of the parent metal. At relatively high fatigue stress, the summary (i.e., the cyclic-plus residual-) stress may exceed the material yield strength; thus, the fatigue cracking should result from the preceding macro-scale plastic deformation. Accordingly, the fatigue failure should occur in the softest microstructural region; thus; the fatigue strength of the welded joint may be inferior to that of the original material.

On the Strength of a 316L-Type Stainless Steel Subjected to Cold or Warm Rolling Followed by Annealing.

The ultrafine-grained microstructures and their effect on the yield strength of a 316L-type austenitic stainless steel processed by large strain cold/warm rolling and subsequent annealing were studied. A kind of continuous recrystallization developed during annealing, resulting in the evolution of uniform ultrafine-grained microstructures with relatively high residual dislocation densities. The development of such microstructure at 973 K led to excellent combination of tensile properties including high yield strength (σ0.2 > 900 MPa) and satisfactory plasticity (δ > 15%). A unique power law function between the annealed grain size and the dislocation density with a dislocation density exponent of -0.5 was obtained for these continuously recrystallized microstructures. A physically justified explanation of the observed structural/substructural strengthening is introduced.

On the Fracture Behavior of a Creep Resistant 10% Cr Steel with High Boron and Low Nitrogen Contents at Low Temperatures.

An advanced, high chromium, creep-resistant steel was subjected to the tensile tests and three-point bending tests of Charpy V-notch specimens at temperatures of -196 to 20 °C. The steel exhibited ductile fracture under tension tests at all of the temperatures studied. The mechanical properties, i.e., strength and uniform elongation, were enhanced with a decrease in temperature down to -140 °C. Transgranular, dimpled fracture remained the primary fracture mechanism under tension. On the other hand, the results obtained with Charpy V-notch specimens suggested the ductile-brittle transition (DBT). Full embrittlement was observed at temperatures of -60 °C and -150 °C upon impact tests and three-point bending tests, respectively, when the unstable crack started to propagate without remarkable plastic deformation. The DBT temperature of -27 °C for the present steel corresponded to the 28 J impact transition temperature, T28J, when the maximum impact stress matched the maximal true tensile stress.

Grain Refinement Kinetics in a Low Alloyed Cu-Cr-Zr Alloy Subjected to Large Strain Deformation.

This paper investigates the microstructural evolution and grain refinement kinetics of a solution-treated Cu-0.1Cr-0.06Zr alloy during equal channel angular pressing (ECAP) at a temperature of 673 K via route BC. The microstructural change during plastic deformation was accompanied by the formation of the microband and an increase in the misorientations of strain-induced subboundaries. We argue that continuous dynamic recrystallization refined the initially coarse grains, and discuss the dynamic recrystallization kinetics in terms of grain/subgrain boundary triple junction evolution. A modified Johnson-Mehl-Avrami-Kolmogorov relationship with a strain exponent of about 1.49 is used to express the strain dependence of the triple junctions of high-angle boundaries. Severe plastic deformation by ECAP led to substantial strengthening of the Cu-0.1Cr-0.06Zr alloy. The yield strength increased from 60 MPa in the initial state to 445 MPa after a total strain level of 12.