Shear-based deformation processing of age-hardened aluminum alloy for single-step sheet production

Bai, Xiaolong; Kustas, Andrew; Mann, James B.; Chandrasekar, Srinivasan; Trumble, Kevin P.

doi:10.1115/1.4052441

Title: Shear-based deformation processing of age-hardened aluminum alloy for single-step sheet production

Journal Article · Fri Oct 29 00:00:00 EDT 2021 · Journal of Manufacturing Science and Engineering

DOI:https://doi.org/10.1115/1.4052441· OSTI ID:1822242

Bai, Xiaolong ^[1]; Kustas, Andrew ^[2]; Mann, James B. ^[1]; Chandrasekar, Srinivasan ^[3]; Trumble, Kevin P. ^[1]

West Lafayette, IN (United States)
Albuquerque, NM (United States)
Purdue Univ., West Lafayette, IN (United States)

Shear-based deformation processing by hybrid cutting-extrusion and free machining are used to make continuous strip, of thickness up to one millimeter, from low-workability AA6013-T6 in a single deformation step. The intense shear can impose effective strains as large as 2 in the strip without pre-heating of the workpiece. The creation of strip in a single step is facilitated by three factors inherent to the cutting deformation zone: highly confined shear deformation, in situ plastic deformation-induced heating and high hydrostatic pressure. The hybrid cutting-extrusion, which employs a second die located across from the primary cutting tool to constrain the chip geometry, is found to produce strip with smooth surfaces (S_a < 0.4 μm) that is similar to cold-rolled strip. The strips show an elongated grain microstructure that is inclined to the strip surfaces – a shear texture – that is quite different from rolled sheet. Furthermore, this shear texture (inclination) angle is determined by the deformation path. Through control of the deformation parameters such as strain and temperature, a range of microstructures and strengths could be achieved in the strip. When the cutting-based deformation was done at room temperature, without workpiece pre-heating, the starting T6 material was further strengthened by as much as 30% in a single step. In elevated-temperature cutting-extrusion, dynamic recrystallization was observed, resulting in a refined grain size in the strip. Implications for deformation processing of age-hardenable Al alloys into sheet form, and microstructure control therein, are discussed.

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Research Organization:: Sandia National Lab. (SNL-NM), Albuquerque, NM (United States)

Sponsoring Organization:: USDOE National Nuclear Security Administration (NNSA)

Grant/Contract Number:: NA0003525

OSTI ID:: 1822242

Report Number(s):: SAND-2021-11772J; 699666

Journal Information:: Journal of Manufacturing Science and Engineering, Vol. 144, Issue 6; ISSN 1087-1357

Publisher:: ASMECopyright Statement

Country of Publication:: United States

Language:: English

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36 MATERIALS SCIENCE
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sheet processing
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