Achieving strength-ductility synergy in cold spray additively manufactured Al/B4C composites through a hybrid post-deposition treatment

doi:10.1016/j.jmst.2018.12.022

Abstract

Abstract:

Cold spray additive manufacturing (CSAM) provides a potential solid state manufacturing route to fabricate variety of aluminum matrix composites (AMCs) with reduced possibility of undesired chemical reactions and residual thermal stresses. This study presents a hybrid (i.e. hot compression + hot rolling) post-deposition treatment to reinvigorate the mechanical properties of cold spray additively manufactured Al/B₄C composites. The as-deposited samples were initially subjected to 30% thickness reduction via hot compression treatment at ~500 °C followed by a hot rolling treatment with 40% thickness reduction in 2 passes. Electron backscatter diffraction (EBSD) and high resolution transmission electron microscopy (HRTEM) results revealed that after hybrid post-deposition treatment (involving 70% accumulative thickness reduction), the aluminum grains in the matrix were extensively refined due to simultaneous operation of continuous dynamic recrystallization (CDRX) and geometric dynamic recrystallization (GDRX). Furthermore, interfacial defects were remarkably reduced while the nature of Al/Al and Al/B₄C interfacial bonding was changed from sheer mechanical interlocking to metallurgical bonding which facilitated efficient transference of applied load to uniformly dispersed bimodal B₄C particles. As a result, ultimate tensile strength (UTS) and elongation (EL) of the as-deposited sample were simultaneously improved from ~37 to 185 MPa and ~0.3% to 6.2%, respectively.

Key words: Cold spray additive manufacturing, Post-deposition treatments, Al/B₄C composites, Dynamic recrystallization, Mechanical properties

Naeem ul Haq Tariq, Lawrence Gyansah, Xiang Qiu, Chunni Jia, Hasan Bin Awais, Chengwu Zheng, Hao Du, Jiqiang Wang, Tianying Xiong. Achieving strength-ductility synergy in cold spray additively manufactured Al/B₄C composites through a hybrid post-deposition treatment[J]. J. Mater. Sci. Technol., 2019, 35(6): 1053-1063.

Figures/Tables 11

Fig. 1. Schematic demonstration of hybrid post-deposition treatment alongside location of EBSD analysis and tensile test specimen.

Fig. 2. Color coded inverse pole figure (IPF) maps (a-c), grain boundary maps (d-f) and misorientation angle distributions (g-i) for as-deposited (a, d, g), HC (b, e, h) and HC + HR (c, f, i) samples.

Fig. 3. Aluminum grain size distribution (a) and fraction of various types of grain boundaries (b) in as-received powder as well as in as-deposited, HC and HC + HR samples.

Fig. 4. Schematic demonstration of CDRX (a) and GDRX (b) mechanisms.

Fig. 5. Pole figures of as-deposited (a), HC (b) and HC + HR (c) samples.

Fig. 6. Kernel average misorientation (KAM) maps for as-deposited (a), HC (b) and HC + HR (c) samples.

Fig. 7. XRD patterns of Al/B4C composite at different processing stages (a) and magnified view of shaded region marked in Fig. 7(a) (b).

Fig. 8. (a) TEM bright field image for HC + HR sample near Al/B4C interfacial region (the top and bottom inserts show SAED patterns of B4C (location 1) and Al matrix (location 2)), (b) high resolution TEM image (with FT pattern inserted) for Al/B4C interfacial region at location 3, (c) TEM bright field image of matrix and (d) formation of GDRXed grains through impingement of serrated grain boundaries in matrix region.

Fig. 9. Room temperature engineering stress-strain curves (a) and comparison of mechanical properties of Al/B4C at different processing stages (b).

Fig. 10. Von Mises stress distributions (a-c), plastic strain distributions (d-f) and stored energy distributions (g-i) in as-deposited (a, d, g) at 0.25% strain interval, HC (b, e, h) and HC + HR (c, f, i) samples at 5% strain interval.

Fig. 11. SEM images of fractured surface of as-deposited (a-c), HC (d-f) and HC + HR (g-i) samples at different magnification.

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Achieving strength-ductility synergy in cold spray additively manufactured Al/B₄C composites through a hybrid post-deposition treatment

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