Microstructure, mechanical properties and deformation characteristics of Al-Mg-Si alloys processed by a continuous expansion extrusion approach

doi:10.1016/j.jmst.2020.11.055

Abstract

Abstract:

In the present work, a double-pass continuous expansion extrusion forming (CEEF) process was proposed for an Al-Mg-Si alloy, in which the diameter of rods was gradually expanded. The microstructural evolution, mechanical properties and deformation characteristics were investigated by utilizing microstructural observations, mechanical testing and a finite element method coupled with a cellular automata model. The results showed that the strength and ductility of the double-pass CEEF processed Al-Mg-Si alloys were improved synchronously, especially in artificially aged alloys. The grain size of the processed Al-Mg-Si alloy rods was refined remarkably by continuous dynamic recrystallization (CDRX) and geometric dynamic recrystallization (GDRX), and the homogeneity of microstructure was gradually improved with increasing number of processing passes. The artificially aged alloy processed with double-pass CEEF and water quenching contained fine (sub)grains and high-density dislocations, which resulted in more needle-shapedβ” precipitates and a larger precipitate aspect ratio than the as-received and air-cooled CEEF alloys owing to the different precipitation kinetics. The severe cumulate strain and microshear bands were found to accelerate CDRX and GDRX for grain refinement between adjacent positions of the parabolic metal flow due to the special temperature characteristics and large shear straining during the CEEF process.

Key words: Al-Mg-Si alloy, Continuous expansion extrusion forming, Microstructure, Mechanical property, Finite element analysis

Ruiqing Lu, Shuwei Zheng, Jie Teng, Jiamin Hu, Dingfa Fu, Jianchun Chen, Guodong Zhao, Fulin Jiang, Hui Zhang. Microstructure, mechanical properties and deformation characteristics of Al-Mg-Si alloys processed by a continuous expansion extrusion approach[J]. J. Mater. Sci. Technol., 2021, 80: 150-162.

Figures/Tables 13

Fig. 1. Schematic diagrams of (a) the double-pass CEEF approach and (b) expansion extrusion die. (c) Picture showing the as-received sample (φ = 10 mm), single-pass CEEF processed sample (φ = 16 mm) and double-pass CEEF processed sample (φ = 28 mm).

Fig. 2. OM, EBSD and misorientation angle distribution images of the as-received Al-Mg-Si alloy rod (φ = 10 mm):(a) OM image, (b), (c) and (d) EBSD inverse pole figures (IPFs), (e), (f) and (g) misorientation angle distribution images.

Fig. 3. OM, EBSD and misorientation angle distribution images of the single-pass CEEF processed Al-Mg-Si alloy rod (φ = 16 mm):(a) OM image, (b), (c) and (d) EBSD IPFs, (e), (f) and (g) misorientation angle distribution images.

Fig. 4. OM, EBSD and misorientation angle distribution images of the double-pass CEEF processed Al-Mg-Si alloy rod (φ = 28 mm):(a) OM image, (b), (c) and (d) EBSD IPFs, (e), (f) and (g) misorientation angle distribution images,(h) enlarged area of EBSD maps of (b).

Fig. 5. TEM micrographs of (a) & (b) the as-received Al-Mg-Si alloy sample (φ = 10 mm), (c) single-pass CEEF processed sample (φ = 16 mm) and double-pass CEEF processed samples (φ = 28 mm) with (d) water quenching or (e) air cooling.

Fig. 6. TEM micrographs of the Al-Mg-Si alloys aged at 175 °C for 8 h: (a) & (b) the as-received sample ( φ = 10 mm) and double-pass CEEF processed samples (φ = 28 mm) with (c) & (d) air cooling or (e) & (f) water quenching. (g) The aspect ratio of rod/needle-shaped precipitates in above samples.

Fig. 7. HRTEM images of the Al-Mg-Si alloys aged at 175 °C for 8 h: (a) the as-received sample ( φ = 10 mm) and double-pass CEEF processed samples (φ = 28 mm) with (b) air cooling or (c) water quenching.

Fig. 8. Mechanical properties of the as-received Al-Mg-Si alloy sample (φ = 10 mm) and double-pass CEEF processed samples (φ = 28 mm) with air cooling or water quenching: (a) microhardness; (b) engineering stress-strain curves.

Fig. 9. Mechanical properties of the as-received Al-Mg-Si alloy sample (φ = 10 mm) and double-pass CEEF processed samples (φ = 28 mm) with air cooling or water quenching after artificial aging (175 °C/8 h): (a) microhardness; (b) engineering stress-strain curves. For the air cooled specimen, additional solid solution treatment at 520 °C for 2 h was implemented before artificial aging.

Fig. 10. Finite element simulation analysis of the second pass CEEF process: (a) effective strain; (b) effective strain rate; (c) deformation temperature and (d) the schematic diagram of the extended extrusion die.

Table 1 Parameters for the CA model used in the present work.

G (MPa)	h₀ (μm^-2)	r₀	m	K
29.484	0.75	2000	0.2	6030

Fig. 11. Simulated microstructures at different locations of the processed Al-Mg-Si alloy: (a), (b) and (c) single-pass CEEF (φ = 16 mm); (d), (e) and (f) double-pass CEEF (φ = 28 mm).

Fig. 12. Distribution of shear strain through the diameter CEEF process. Schematic illustration of the parabolic metal flow and apparent shear angle φi. Variation of shear strain in the different regions of the CEEF processed samples.

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