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Effect of Coarse Eutectic-Originated Particles on the Microstructure and Properties of the Friction Stir-Processed Al-Mg-Zr-Sc-Based Alloys

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Abstract

Friction stir processing (FSP) is a promising technique to refine grains and improve the mechanical properties of metallic materials. The current work compares a FSP-ed Al-Mg-Sc-Zr-alloy with fine nanoscale L12-structured Al3(Sc,Zr) precipitates and an alloy modified by 0.9 wt.%Fe-0.9 wt.%Ni containing both fine Al3(Sc,Zr) and coarse Al9FeNi-phase particles of solidification origin. The influences of both secondary-phase particles and FSP parameters on the microstructure, mechanical properties, and superplasticity of the alloys were examined. During FSP, the temperature increased to ~ 520°C, a mean size of the Al3(Sc,Zr) precipitates increased from 12 nm to 31 nm, whereas a size of the Al9FeNi particles decreased from 1.9 ± 0.1 µm to 1.1 ± 0.1 µm and exhibited a uniform distribution in the matrix. The reference alloy with fine Al3(Sc,Zr) precipitates exhibited a non-uniform partially recrystallized grain structure, whereas the modified alloy with both fine Al3(Sc,Zr) and coarse Al9FeNi-particles exhibited equiaxed fine grains after FSP. In the stirred zone of the reference and modified alloys, the average grain size was 3.3 ± 0.1 µm and 4.0 ± 0.3 µm, respectively. As a result, the modified alloy exhibited an improvement in ultimate tensile strength and elongation-to-fracture compared with the reference alloy by 22% and 40%, respectively. The fine Al3(Sc,Zr) and coarse Al9FeNi particles and their uniform distribution after FSP provided effective grain refinement by Zener pinning and particle-stimulated nucleation mechanisms resulting in the modified alloy's high strain rate superplasticity.

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Acknowledgements

The study was funded by the RSF Grant # 22-79-00215. The raw/processed data required to reproduce these findings cannot be shared at this time as the data also forms part of an ongoing study.

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Authors and Affiliations

  1. Mechanical Engineering Department, Faculty of Engineering at Shoubra, Benha University, Cairo, 11629, Egypt

    Ahmed O. Mosleh

  2. Physical Metallurgy of Non-Ferrous Metals, National University of Science and Technology “MISiS”, Leninsky Prospekt, 4, Moscow, Russia, 119049

    Olga A. Yakovtseva, Anna A. Kishchik, Anton D. Kotov & Anastasia V. Mikhaylovskaya

  3. Mechanical Engineering Department, Faculty of Engineering, King Abdulaziz University, P.O. Box 80204, Jeddah, Saudi Arabia

    Essam B. Moustafa

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Mosleh, A.O., Yakovtseva, O.A., Kishchik, A.A. et al. Effect of Coarse Eutectic-Originated Particles on the Microstructure and Properties of the Friction Stir-Processed Al-Mg-Zr-Sc-Based Alloys. JOM 75, 2989–3000 (2023). https://doi.org/10.1007/s11837-023-05712-x

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