Showing papers by "Sushanta Kumar Panigrahi published in 2023"

A comprehensive study on size-effect, plastic anisotropy and microformability of aluminum with varied alloy chemistry, crystallographic texture, and microstructure

Abstract: Fabrication of microparts with large aspect-ratio and complex shapes remains a huge challenge for industries and microforming is a potential solution to manufacture such microparts. However, similarity in specimen-deformation and microstructural length scales during microforming results in size effect, leading to unpredictable plastic behavior and increased process scatter. One approach to counter size effect is by engineering suitable microstructure in the material. In the present work, three grades of Al (AA1070, AA5083, AA2014) with unique alloy chemistry and microstructural profile are processed by cryorolling (CR) to 95% thickness reduction. By imparting controlled postprocess annealing on the CR materials, three distinctive microstructures – (i) ultrafine grained (UFG) with average grain size around 1 μm, (ii) fine grained (FG) with average grain size near to 5 μm, and (iii) coarse grained (CG) with approximate average grain size of 20 μm are engineered. The influence of alloy chemistry, grain boundary engineering and crystallographic texture on microformability are studied. For pure Al (AA1070), the UFG and FG microstructures show superior microformability than the CG counterparts. The equiaxed UFG grains present in these microstructures mitigate the size effect abnormalities by increasing the number of grains in the deformation volume and uniformly distributing the complex microforming strain via grain boundary mediated plasticity. Their corresponding texture containing strong Copper mixed with scattered Cube elements promotes in-plane strain condition and high resistance to localized thinning. Also, the material shows near-zero planar anisotropy that leads to a homogenous in-plane strain distribution. Unlike pure Al, the UFG and FG Al alloys suffer from increased strain localization due to presence of solute clouds and nanoprecipitates. They influence strain-aging (Portevin–Le Chatelier effect), strain gradient hardening phenomenon, and shear propensity during failure of the Al alloys. A composite texture consisting of a combination of Brass, Dillamore, S, and β-fiber elements in the Al alloys is found to be detrimental to their microformability. The Dillamore texture is contributed by formation of adiabatic shear bands during deformation of Al alloys.