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Strain hardening and microstructure evolution in ECAP-processed ultrafine-grained metals: a comparative study of copper, aluminum, and magnesium alloys

  • The Physics of Metal Plasticity: in honor of Professor Hussein Zbib
  • Published:
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Abstract

This study presents a comparative analysis of texture evolution, deformation mechanisms, and dislocation density evolution in pure copper, Al-1100 alloy, and Mg AZ31 alloy subjected to equal-channel angular pressing (ECAP). For that purpose, a unique grain fragmentation model combining continuum dislocation dynamics with Taylor-Lin crystal plasticity is presented. Copper and aluminum alloys, with their face-centered cubic (FCC) crystal structures, exhibit similar micromechanical processes during grain fragmentation. The post-ECAP textures for both materials align with ideal orientations, indicating a rotation of grains around the center of the flow direction. On the other hand, the magnesium AZ31 alloy, with its hexagonal close-packed (HCP) crystal structure, displays a rolling-like texture. Al-1100 showed high dislocation multiplication rate favored by dislocation glide, while Mg AZ31 displayed slower dislocation density evolution at 200 °C which can be associated with dynamic recrystallization and twinning low activity. Indeed, driven by elevated temperatures, dynamic recrystallization could form new grains, resulting in a gradual increase in dislocation density. Furthermore, the comparison of average grain size reduction rates aligns with the dislocation density findings, with aluminum alloys experiencing significant grain fragmentation and Mg AZ31 alloy undergoing the slowest rate of grain fragmentation. The employed continuum dislocation dynamics (CDD) coupled with a crystal plasticity modeling approach enables the prediction of material responses, offering a powerful tool for understanding and optimizing deformation behavior. Further research opportunities lie in exploring additional factors and refining the understanding of deformation behavior in FCC and HCP materials, as well as expanding the applicability of the modeling approach to other materials and processing techniques.

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Data availability

The data and code associated with this manuscript are available upon request. Interested readers can obtain access to the data and code by contacting the authors directly. We are committed to promoting transparency and facilitating reproducibility in scientific research. Therefore, we encourage researchers to reach out to us for any inquiries or requests regarding the availability of the data and code utilized in this study.

Notes

  1. The Hall–Petch stress is inversely proportional to the square root of the grain size D and can be expressed as $${\tau }_{HP}^{s}={K}^{s}/\sqrt{D}$$, where $${K}^{s}$$ is the Hall–Petch parameter related to each slip system.

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Acknowledgements

The authors gratefully acknowledge the American University of Beirut and the National Council for Scientific Research of Lebanon (CNRS-L) for granting financial fellowship to Ali Al-Hadi Kobaissy to support his doctoral studies. The authors gratefully acknowledge the University of Michigan-Dearborn College of Engineering and Computer Science for granting financial fellowship to Ossama Abou Ali Modad to support his doctoral studies.

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Authors and Affiliations

  1. Department of Industrial and Manufacturing Systems Engineering, University of Michigan-Dearborn, Dearborn, MI, 48128, USA

    Georges Ayoub & Ossama Abou Ali Modad

  2. Department of Mechanical Engineering, American University of Beirut, Beirut, Lebanon

    Ali al-Hadi Kobaissy

  3. Department of Mechanical Engineering, Alfaisal University, Riyadh, Saudi Arabia

    Mutasem Shehadeh

  4. Department of Mechanical & Aerospace Engineering, Clarkson University, Potsdam, NY, 13699, USA

    Ioannis Mastorakos

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  1. Georges Ayoub
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  3. Ali al-Hadi Kobaissy
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  4. Mutasem Shehadeh
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All persons who meet authorship criteria are listed as authors, and all authors certify that they have participated sufficiently in the work to take public responsibility for the content, including participation in the concept, design, analysis, writing, or revision of the manuscript. Furthermore, each author certifies that this material or similar material has not been and will not be submitted to or published in any other publication before its appearance in the Journal of Materials Science. GA, OAAM, AHK, MTS, and IM were involved in conceptualization, methodology, formal analysis, investigation, resources, data curation, and writing—review and editing. GA and AHK were involved in software. GA, OAAM, and AHK were involved in validation, writing—original draft, and visualization. GA was involved in supervision, project administration, and funding acquisition.

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Correspondence to Georges Ayoub.

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Ayoub, G., Modad, O.A.A., Kobaissy, A.aH. et al. Strain hardening and microstructure evolution in ECAP-processed ultrafine-grained metals: a comparative study of copper, aluminum, and magnesium alloys. J Mater Sci 59, 4995–5024 (2024). https://doi.org/10.1007/s10853-023-08942-1

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