How to Make Strong Metals

With High Ductility?

Yan Beygelzimer

Donetsk Institute of Physics and Technology

National Academy of Sciences of Ukraine

1
 Outline
1. How do we try to do it?
First way: fragmentation
Second way: consolidation
2. How do we try to explain and to
predict it?
Mechanics of the processing
Structure, ductility, strength
3. Final Thoughts
2
 How do we try to do it?

•Severe plastic deformation (SPD)

•Twist Extrusion

•First way: Fragmentation

•Second way: Consolidation

3
 Some of the SPD Techniques

High Pressure Torsion Equal Channel

Angular Extrusion

Twist Extrusion
3d Forging
(Y.Beygelzimer, 1999) 4
The idea of TE:

Twist channel

5
 The idea of TE:

Twist channel

Equivalent strain e1

The shape and the dimensions of

the work-piece do not change!
6
 The idea of TE:

Equivalent strain e2

Twist channel

Repeated twist extrusion leads to grain refinement

7
 Twist Extrusion: Two in One

Fragmentation

Twist
Extrusion
Consolidation

8
Fragmentation

•Grains refinement. UFG materials

•Breaking of a brittle particles

9
Why should we care about grain
refinement during severe plastic
deformation?

This is one of few effective techniques for

obtaining ultrafine-grained (UFG) materials

10
 Grain refinement

Coarse

SPD

11
Grain refinement

UFG

SPD

12
 Ultrafine-Grained Materials

 What are they?

– Metals with grain size ~10-1000 nm
 Why are they appealing?
– Significantly improved properties
– Qualitatively different properties not seen
in conventional materials

13
 High strength and ductility
of UFG materials

R.Z. Valiev, I.V. Alexandrov, Y.T. Zhu and T.C. Lowe, “Paradox of
Strength and Ductility in Metals Processed by Severe Plastic
Deformation,” J. Mater. Res. 17, 5-8 (2002). 14
 Twist extrusion of the Ti

50 mm 50 mm

Initial state After 3 passes

15
Twist extrusion of the Ti

16
SPD of the Ti

17
Plates for traumatology
are made of UFG Ti

18
 Twist extrusion of the Al-Mg-Sc-Zr alloy
Chemical composition:
Al - 3 wt.%Mg - 0,3 wt.%Sc – 0,10 wt.%Zr

Initial grain size dav=100 µm

Twist extrusion: T=280-300ºC
Standard direct extrusion: 5 passes CW + 1 pass CCW
T=280-300ºC

dav= 0.455 µm dav=0.325 µm

dmin= 0.129µm dmin= 0.077µm
dmax=1.032 mm dmax=0.671 mm 19
 SPD of the Cu
Uniform
State Yield stress, Tensile strength elongation,
MPa MPa %

As received 80 145 40
TE, 3 passes, 393 426 18
with BP

* ECAE, 2 320 360 14

passes
* ECAE, 16
passes, 420 440 15
without BP
* ECAE, 16
passes, 440 470 25
with BP
20
*N. Krasil’nikov, R.Valiev
 ECAE of the Cu

Wei Wei, Guang Chen, Jing Tao Wang, Guo Liang Chen
Journal of Advanced Materials 2005 (in press)

21
 Three present-day ways to increase
strength and ductility of UFG materials

•Cryogenic processing to produce a bimodal grain

structure
•Formation of second-phase particles to modify the
propagation of shear bands
•Developing aging and annealing treatments that can be
applied to the UFG materials in the post-processed
condition

22
Breaking of a brittle particles

SPD

23
Breaking of a brittle particles

SPD

24
 TE of secondary Al alloy
Al-88%; Si-9,5% …

Initial state 1 pass

σy=50МPа δ=1% σy=205МPа δ=14%

25
Twist Extrusion of phosphorous Cu (P 9%)
Initial state 1 pass

Treatment YS, МPа d,%

YS,MPa
Direct Extrusion, µ=4.5 360 4
Twist Extrusion 420 11

Back pressure = 200 MPa, T= 623 K 26

 Twist extrusion of the Al-Mg-Sc-ZR alloys
Chemical composition:
Al – 3 wt.%Mg - 0,3 wt.%Sc – 0,15 wt.%Zr

SEM, As-deformed structure,

SEM, As-cast structure TE – 5 passes, Tdef=280-300ºC
Cross-section Longitudinal section

0.5µm 0.5µm

27
Consolidation

SPD

28
Consolidation

SPD

29
 Consolidation of nanostructural
Cu powder by Twist Extrusion
Back pressure = 200 MPa, T= 473 K

Initial powder, D=250 µm 1 pass 2 passes

Compression test Tensile test
after 2 passes: after 2 passes:
Yield stress = 450 MPa Yield stress = 200 MPa
Breaking strain = 28% Breaking strain = 15% 30
Consolidation of nanostructural
Cu powder by Twist Extrusion

Diameter of the
Density, coherent-
State
% scattering region
L, nm
powder - 100
TE, 1 path 99.2 36
TE, 2 paths 99.6 55

31
 Consolidation of amorphous Al86Ni6Co2Gd6
melt-spun ribbons by Twist Extrusion
550 1,0

Volume density of crystals

Microhardness (kgf/mm )

Al86(Ni,Co)8Gd6
2

0,8
500

Intensity (a.u.)
0,6
450
0,4

400 0,2 573K

Ribbons
513 K
Extrusions
0,0 AQ
350
300 350 400 450 500 550 20 40 60 80 100 120 140
Extrusion temperature (K) 2 (deg)

Microhardness and the volume

fraction of the amorphous phase in the X-ray diffraction patterns
compacted samples.
32
 Consolidation of the cutting of the
secondary Al alloy by Twist Extrusion

d=12 mm

Yield stress =180-220 МPа; d= 20-24%

33
 How do we try to explain
and to predict it?
•The questions

•Mechanics of the processing

•The Problem

•The Model

•Predictions
34
 The questions

•Parameters of the process?

•Strength and Ductility of the materials?

•Structure of the materials?

35
Mechanics of metal flow

36
 Stream lines

1
4

2 5

3 6 7 8
37
 Kinematically-admissible velocity field

1. Volume constancy condition


divV  0

2. Boundary condition

   
V  V0 V n  0
38
 Kinematically-admissible velocity field

 
V  rotA - form function
 0

 Ax  0.5V0 y;
  0
 Ay  0.5V0 x;
 V0 tg
 z
A   xy   ( x, y, z ) P( x, y, z );
 R

P- function which is varied  0

39
 Finding function P on the
experimental stream lines

Experimental stream line

Theoretical stream line

 ( z)
0
p ( z)

3

0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36

0 z 36

40
 Metal Deformation under Twist Extrusion

We showed that most of the deformation achieved by Twist

Extrusion is Simple Shear at the ends of the twist channel
41
 Equivalent strain for TE pass
The average equivalent strain during one pass
e=tan()

Distribution of the strain

500

400

300

Z Axis
200

100

0 8
-15 6

Yield stress, Cu -10

-5

X Ax
0
5 -4
-2
0
2

xis
4

is 10
-8
-6 YA
15

42
 The Problem with
Theoretical Model

One of the main problems faced by any

theoretical model is the need to capture the
multi-level character of plastic deformation

43
 Metal Structure is Determined by the
Image of the Loading Process
P4,T4,..

Grain refinement
.
e2

P3,T3,..
.

P2,T2,..
.
P1,T1,..
.
e1
44
But … The Image of The Loading Process
depends on this structure

The reason is that the structure defines the mechanical

properties of the materials.

45
 Macro-Micro Interdependency

Metal Structure

Image of the Loading

Process

46
 The Problem

• We are trying to produce a given

ultrafine homogeneous structure
• In reality, however, the specimen
may respond with a number of bad
things: highly inhomogeneous
structure, deformation localization or
fracture.
• The reason why this happens is
precisely the “Interdependency”.

47
 Our approach to capture the
interdependency

Internal parameters

Continuum model FEM

Internal parameters will allow us to account for the

interdependency between the stress-strain state and
the structure. 48
Internal parameters serve as special
envoys representing the micro-level
processes at the macro-level

S


49
Model of the material

50
 Constitutive equations of the
Mises’s model
f  ij 
f  ij   0, eij  
 ij
RVE

 s 
2

f  ij     
2
 e  0
 3

1  1  1 
   ikd ik      ik  d ik   ik  d ik  
3  3  3 
51
 Porous body with structurally
inhomogeneous matrix

RVE
 s 
2

f  ij  

2
f  
ij 
2
 2
 
 1 
 s 
2

 3   
     3 

  e0
e
 
    1   k 0   
      

Beygelzimer Y. et al., (1994) Engin. Fracture Mech., 48, N5

Beygelzimer Y. Proceedings of International Workshop on Modelling

52
of Metal Powder Forming Processes, Grenoble, France, July 21-23, 1997
 Plausible reasoning
RVE

 s 
2

f  ij     
2

 3

   s
2

f  ij  
2 2
  1     
     3 

53
Loading surfaces
=0 



54
 Loading surfaces of the cutting
of the secondary Al alloy

, 150
, M Пa
MPa
100
4

3
50 2
1
0 100 200 300 400 500 600 700 800

,M Пa
P,PMPa

: 1- 30%, 2- 20%, 3- 10%, 4- 3%.

55
 Porous body with structurally
inhomogeneous matrix at <<1

 s
2

f  ij   6a    
2 2
  
 3 
d 
   6 3a 
d s

,s (d) a

56
 Breaking of a brittle particles
  1 exp(  )  2 1  exp(  )

Beygelzimer Y., Shevelev A. On the Development of Fracture Models for

Metal Forming// Russian Metallurgy (Metally), Vol., N5, p. 452–456, 2003 57
 The model of grain refinement
and viscous fracture

Beygelzimer Y. Grain refinement versus voids

accumulation during severe plastic deformations of
polycrystals: Mathematical simulation, Mechanics of
Materials, V. 37, N7, p. 753-767, 2005

58
 Main characters of the Model
• Accumulative Zone – a “spring”, the
part of crystals in which dislocation
charges accumulate during plastic
deformation; AZs emerge due to the
inhomogeneity of shear along the
Scale

500 nm sliding plane.

• Void – a bit of an emptiness

0

• Embryo – an embryo of high-angle

boundary (a partial disclination)

59
Pictures of Main Characters

60
 The Birth of an Accumulative Zone

There are regions of polycrystals where dislocations get

plugged during plastic deformation. Such regions cause
bendings of the crystalline lattice. 61
 The Birth of an Accumulative Zone

The model postulates that AZs

emerge in two places:

1. hurdles that exist in

polycrystals before
deformation

2. high-angle boundaries that

emerge during deformation.

62
Relaxations of Accumulative Zones in
coarse grained materials

There are different relaxation mechanisms for

accumulative zones. When talking about large
cold deformations, we will distinguish two main
mechanisms:

1. Emergence of high angle boundaries

(leading to grain refinement)
2. Emergence of voids (leading to fracture)

63
Relaxations of Accumulative Zones in
coarse grained materials

64
 Boundary sliding

b1 b1 b1
1  0.99  0.80
boundary b1 b2 b2 b2
1.5

b2 f
1

f1( s)
0.5
f2( s)

f3( s)
f 0
b1
0.5

1
0 0.1 0.2 0.3 0.4 0.5
b2 ss
Prandtl model b1
65
Relaxations of Accumulative Zones in
ultrafine grained materials
Sliding plane

66
Relaxations of Accumulative Zones in
ultrafine grained materials

67
Relaxations of Accumulative Zones in
ultrafine grained materials

68
 Equations of the Model
Classical Plasticity Theory:

G(,)=0 General

P(,;µ)=0 Constitutive

Proposed model with internal parameters capturing the structure:

G(,)=0 General

S µ)=0
P(,; S,; 
Constitutive

K(S,, ,;µ)=0 Kinetic

69
 Loading function

  s S 
2
* 
f  ij ; , S   6a    
2 2
  
 3 

3
3
  C3 N d c v
* 2

70
 Kinetic equations

 dN Quasimonotonic
 d  C1  C 2 C5 N b F S   C3  C 4 N loading
 N  0 Nb  0
 dN b S  0 0
 d  C 4 N  C5 N b

 dS C N N n1  0 Nb n1  Nb n 
  5 b
 d S  S 0 Sn1  Sn  0
.  n 1   n
 3
 d 2 d 3 v  C  N  0 Nb  0
 d  C 3 N c 6
 S  0 0

Cyclic
71
loading
Prediction

72
 Prediction (i)
As   :

N  0, Nb  0,
d  dc , 0
Ideal Plasticity Land
Metals don’t fracture and don’t harden under sufficiently
high pressure when equivalent strain is very large, i.e.,
metals become ideally plastic.

The reason is boundary sliding

73
 Prediction (ii)

Ductility grows
for sufficiently large equivalent strain

The reason is boundary sliding

74
 The term responsible for the birth of voids

d p 3
     B 
*
 *    C3 N  d c3v
2
d 
0.015

0.01 с
alpha

*
0.005

αDuctility
* decrease
grows
forfor

0
sufficiently
sufficiently
0 large 5strain.
large strain. 10
strain

75
 Prediction (iii)

P
Grain refinement intensity grows and
fracture decreases with the increase of
pressure in the center of deformation. 76
The reason is p grows with pressure increase

0.1 420 840 1120 p, MPa

1
 Nс   p  p 3
S   D   0  
 с 

77
Correspondence with experimental results:
Influence of pressure on the microstructure of
molybdenum at hydroextrusion:

e=0.36
30mm

e=0.60

e=0.92
Pb

Pb = 0,1 MPa Pb = 800 MPa

78
Correspondence with experimental results:
Effect of pressure on fragment size distribution
Hydroextrusion of molybdenum (e=0.6).

f,%
40

20 , GPa

l, 100 µm
79
 Use in Twist Extrusion
Twist Extrusion based
on hydro-mechanical
extrusion

Twist Extrusion based on

mechanical extrusion with
backpressure 80
Model-based prediction for Twist Extrusion

- Рb  0.1 MPa
- Рb = 1000 MPa

81
 Prediction (iv)
To get intense grain refinement, one needs to choose
deformation schemes with small value of ductility
and to perform deformation under pressure.

Grain refinement intensity is typically higher for

simple shear than for uniaxial elongation

82
 The reason is simple shear has
smaller ductility (under the same
c pressure).
1
 Nс   p  p  3
S   D   0  
 с 

c(0), tension c(0) is the metal

under pressure ductility at p=0
c(0), torsion

3p с(0) S


Ductility diagram, steel 08X18H10T
(Experiment data V.Kolmogorov, et al., 1986) 83
Ductility diagrams
for various metals
show that, as a rule,
ductility с(0) of
tension greater than
that of torsion.
(Experiment data
V.Ogorodnikov and
I.Sivak, 1999)

84
 Prediction (v)

Quasi-monotone deformations provide higher grain

refinement intensity than cyclic deformations.
0.8

0.8
0.6
NN,,1/mkm^2
mm-2

0.6

1/mkm
S, S,mm -1
0.4
0.4

0.2
0.2

0 0
0 0.1 0.2 0.3 0.4 0.5 0 0.1 0.2 0.3 0.4 0.5

 
strain strain
85
Cyclic deformations provide higher ductility than
quasi-monotone deformations

0.003

0.002
porosity
porosity

C5

0.001

0
0 0.1 0.2 0.3 0.4 0.5


strain
86
In order to increase the intensity of grain
refinement under cyclic deformation, one has
to increase the amplitude of deformation.
For example, in Twist Extrusion we combine
clockwise and counter-clockwise dies.

87
 clockwise

clockwise

88
 counter-clockwise

clockwise

2A

89
To avoid cyclic deformation we combine Twist Extrusion
with Spread Extrusion

Twist Extrusion Spread Extrusion

90
 Prediction (vi)
Sufficiently high pressure in the center of
deformation prevents strain localization

P P

Layers of the voids

91
 Prediction (vii)
Grain size distribution
0,52
3
0.5 2
f(d),1/mkm

f, f,

f(d)/S
mm 1 1 mm 11

0
0 5 10 15 0
0d
d , mm
1 2 3
d, mkm c
d , mSdm

Self-similar stage When there are

fragments with size dc
92
 Self-similarity of Experimentally
Obtained Distributions
6 1.5

f,4 1
f, mkm^(-1)

=4.61
93%
mm 1 f d

fxM(d)
2 1.07
46% 0.5

. 0.28
0

d , md, m
0 0.5 1 1.5 2 2.5 0
0 0.5 1 1.5 2 2.5 3
mkm
d
d/M (d)

Cu, torsion d
(V.Panin et al., 1985)

93
 Prediction (iv)
During the self-similar stage of grain refinement, the fragment
boundary mesh in the cross-section of the specimen represents
a fractal set with dimension , 1< <2.

1
S 
 1
d
.

1< <2 - fractal dimension.

During the self-similar stage  is constant

94
 s  S

1
s  Hall-Petch

.
d
were     1, 0   1
During the self-similar stage  is constant
95
 When sufficiently many indivisible fragments of
size dc appear, the self-similarity of the
boundary mesh gets violated. In this case


1
S
d
.
s 
1
d

96
 Simulation of the grain refinement
processes by Cellular Model

Initial grain

RVE initial state

Plastic deformationD
Outer stress
D0
RVE new state Deformation
Stress on each
continues. Rotation
element n moments appear М
М
Extension DnDt
and rotation nDt
Moment stresses
of each element relax through grain
splitting

Beygelzimer Y., et al., Philosophical Magazine A, 79, N10, (1999)

97
Limiting Grain size distribution
(Cellular Model)

Cu

10µm

Grain size, μm
98
Final Thoughts

99
 What do we hope for?

One can substitute the classical plasticity model by the

above model in any FEM package to directly compute the
stress-strained state of a metal and its interdependence with
the structure

S 

Continuum model FEM

100
What do we hope for?

101
 What do we have?

• The model is relatively new

• The limits are not entirely explored
• A long way toward good parameter estimation
… but there are grounds for hope

102