Effect of Severe Plastic Deformation Involving Ecap of Aluminum 2024 Alloy Beryl Composites on the Mechanical Properties

doi:10.21203/rs.3.rs-2878325/v1

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Effect of Severe Plastic Deformation Involving Ecap of Aluminum 2024 Alloy Beryl Composites on the Mechanical Properties

https://doi.org/10.21203/rs.3.rs-2878325/v1

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The adoption of Aluminum Metal Matrix composites has gained popularity and widespread application in view of their light weight and superior mechanical strength compared to the un-reinforced alloy system. Much improved characteristics have been derived based on the adoption of secondary processes such as rolling, forming, drawing and plastic deformation. In this context, the preparation of Al2024 alloy, containing Beryl particles as reinforcement is envisaged for getting better properties in terms of strength and hardness for structural use in aerospace industry. Further enhancement in properties to strengthen the alloy may be possible by subjecting it to severe plastic deformation, especially Equal Channel Angular Pressing (ECAP) process.

The present work focuses on developing Al 2024 alloy composites containing Beryl particles at 6 wt.%, through stir cast method. This is followed by ECAP process carried out in the annealed condition. This facility has been designed and developed in house. Following this, the mechanical properties, involving tensile strength, % elongation & hardness have been evaluated for the ECAP processed Al2024 Beryl samples and the values thus obtained are compared with those derived on samples without Beryl additions. The microstructures of the samples, for key stages of the work, have been recorded. Further, the fracture morphology of ECAP processed samples have been examined and analyzed using SEM/EDAX and correlated with the tensile strength data. The ECAP with pass II processed samples have shown higher tensile strength and hardness as well as good grain refinement in the matrix compared to annealed Al alloy sample.

Mechanical Engineering

Materials Engineering

Severe Plastic deformation

Equal Channel Angular Pressing

Tensile Strength

Hardness

Microstructure

SEM

% Elongation

Grain Size

Aluminum 2024 is well known for its excellent strength-to-weight ratio, low density. The aluminum 2024 alloy is comprising of aluminum, copper, and magnesium as major elements, which makes it strong, ductile, and resistant to fatigue [1–3]. Now, coming to the composites world, Aluminum 2024 metal matrix composites (MMCs) incorporate a reinforcing material, usually in the form of ceramic or metallic particles or fibers, with the main advantage of enhancing the strength, stiffness, machineability, weldability and wear resistance. It is ideally suited for demanding applications. such as aerospace, automotive, and defense sectors. It may be recalled that different types of reinforcement materials are used, including silicon carbide, alumina, boron carbide, titanium carbide, Beryl and tungsten carbide [4–8]. Among the reinforcement materials tried to produce MMC’s, hardly a few literatures could be cited regarding the deployment of Beryl particles in Al 2024 matrix and the connected information on the properties. The Beryl addition enhances the strength, hardness as well as wear resistance [8–11]. Hence this particular combination has been taken up in this work with main objective of studying the influence of Beryl addition to Al 2024 on the mechanical properties of the composites. It is also known that the characteristics may be improved further by adopting supplementary processes such as rolling, forging, shot peeing, plastic deformation. In this direction, SPD (Severe Plastic Deformation) is one such method needs further attention [12–14].

1.1 Plastic Deformation

Severe plastic deformation (SPD) is a method of producing ultrafine-grained materials, subjecting them to a high degree of deformation under high pressure or shear forces. The aim of SPD is to produce materials with superior mechanical properties, such as high strength, improved ductility, and enhanced wear resistance. There are several techniques used for severe plastic deformation, including equal channel angular pressing (ECAP), high-pressure torsion (HPT), and accumulative roll bonding (ARB). In ECAP, the material is passed multiple times through a die, which changes the cross-section of the material, leading to grain refinement. In HPT, the material is subjected to a large shear force, causing the grains to rotate and align in new positions in different orientations. In ARB, the material is repeatedly rolled between two rollers, leading to a layered structure and bring in grain refinement. This improved grain structure leads to significant improvement in the mechanical properties, as well as greater resistance to corrosion and wear. SPD is also a cost-effective method for improving the properties of materials, as it does not require special equipment or expensive materials [15–17]. Overall, severe plastic deformation is an important technique for producing materials with superior properties, and it is appropriately used in industries, to get specific advantages. Equal channel angular pressing (ECAP) is a process used in metallurgy to modify the properties of metal alloys, including aluminum metal matrix composites (Al-MMCs). ECAP involves the deformation of materials through a channel in which a metal is subjected to repeated cycles of deformation process. Here the refinement of the grain structure takes place leading to better mechanical properties especially tensile strength and ductily. However, the effect of SPD on Al-MMCs depends on many other factors, including the composition of the matrix, the type and amount of reinforcement, and the processing conditions used during the ECAP. The researchers and manufacturers are exploring the ways and means to optimize the processing conditions and refine the properties involving ECAP in MMC’s. Now, coming to the type of reinforcement and its content, beryl being a mineral has several popular varieties, including emerald, aquamarine and morganite. It is a cyclosilicate with a chemical composition of Be₃Al₂(SiO₃)₆. It is typically found in the granite and pegmatite rocks of hydrothermal veins and possess a hardness of 7.5-8 in the Mohs scale. The Beryl is used as a flux in the production of steel, as well. Its unique physical and chemical properties make it a precious mineral. In this work, Al2024 containing 6 wt.% of Beryl particles subjected to ECAP with I and II passes followed by mechanical (Tensile Strength, % elongation, Surface Roughness, Hardness) as well as metallographically investigations (Microstructure and Grain Size). Another point, it is worth mentioning here is that the Al Beryl MMC’s developed may find usefulness in bush/bearing application used in machineries like shafts, gears pumps, motors etc [11].

2.1 Materials

In this work, the ingots of aluminum 2024 has been procured along with reinforcement material Beryl in the form of powder.

The powder sample has been subjected to X-Ray diffraction technique to check and confirm the phases present in it. The particle size of Beryl mineral is determined using Malvern particle size equipment. Figure 2.1 gives the SEM image of the Beryl particles used in this work. The average particles size of Beryl particles obtained is 143µm.

2.2 Methods

2.2.1 Stir Casting

The stir casting route has been followed to develop Al 2024 Beryl composites and the details may be obtained from another report [11]. As regards the SPD process involving ECAP is concerned, they are covered in greater detail in the reference report [11] including the beneficial effect of the process with respect to the application part.

2.2.2 Characterization work

The density and porosity parameters have been carried for the Al2024 Beryl composites as per the ASTM standard [18]. The tensile strength and % elongation have been measured accordingly to ASTM standard [19]. The Vickers hardness (VHN), surface roughness and grain size have been measured as per the ASTM standard guidelines [20].

The representative samples considered in each measurement are 5 in numbers and finally the average value of the five readings has been reported. The variations in the results obtained in all the tests are in the range ± 1% and the error determined is as per the ASTM standards [21].

3.1 X-Ray Diffraction Data (XRD)

The phase analysis of the Al Beryl composites analyzed using XRD technique are presented in Fig. 3.1.1.

It clearly shows the presence of Al, Cu and Beryl phases in the matrix.

3.2 Density and Porosity

Table 3.1
Sl No	Particulars	ρth (g/cm3)	ρact (g/cm3)		Porosity (%)
			AN	EP II	AN	EP II
1	0% Beryl	2.78	2.75	2.77	1.08	0.36
2	6% Beryl	2.79	2.76	2.78	1.07	0.35

The Table 3.1 presents the theoretical and experimental densities calculated and measured, respectively. The Al 2024 and beryl possess densities of 2.78 and 2.65 g/cm³, respectively. The density is an important characteristic to be determined for any material system, since it reflects on the weight as well as the porosity level or any other type of defects like blow holes, shrinkage, porosity, inclusion etc, that would have originated during the casting process. While the density of Al 2024 2% Beryl composite in the annealed condition is 2.75 g/cm³, on the other hand, the density values of the ECAP processed composites are nearly same as that of the theoretical density values. This demonstrates unequivocally that ECAP has made a significant impact in lowering the porosity value that exist in the casting. The density value decreases during the ECAP process, as the material is continuously subjected to high strain rates. Similar findings are reported by Balog et al. [22], wherein Al-AlN composites processed with ECAP have attained greater than 98% of the theoretical value. In this work also, the same trend is noticed for Al-Beryl composites containing different levels of Beryl particles.

3.3 ECAP process influencing Surface hardness (SH) and Surface Roughness (SR)

As regards the ECAP process of Al2024 alloy and its composite, the hardness increased in the ascending order AN, EPI and EPII, wherein AN is exhibiting the lowest hardness and UTS, on the other hand EPII is showing the highest. The value EPI is showing in between AN and EP II.

Now coming to the literature aspects, it is reported by A. Muralidhar et al. [23], increasing the number of passes during ECAP, the hardness level has increased and at the same time, the grain refinement has taken place. The same behavior is seen in the present work also and hence it is in line with the published [23] work. The study by Lokesh and Mallik [24] regarding the effect of ECAP on the mechanical properties and structural features in Al6061-SiC_p composites produced by stir cast method showed increase in UTS as well as hardness for the ECAP processed (three passes) samples. It is further reported that the better mechanical properties obtained are attributed to the substantial decrease in the grain size. The work done by the same authors have reported [25] enhancements in strength & hardness as well as grain refinement in Al6061-Grp composites made by stir cast technique. Ramesh Kumar et al. [26] reported the beneficial effect of ECAP in Al5083 alloy at room temperature, wherein the hardness has increased with increase in four number of passes. The microstructural evolution and strengthening mechanism of Mg alloy processed through ECAP (2 passes) have been reported by Gopi et al. [27]. In this particular study, two passes of ECAP have enhanced the hardness, increased the UTS and at the same time grain size decrease is seen. The hall Petch equation [28] also reports the relationship exists between the hardness and grain size. As reported, [28] higher the hardness, finer is the grain size. This is covered in detail in section 3.5 down the text.

As regards the surface roughness (SR) it is observed that the ECAP processed with pass II samples have aided in reducing the surface roughness parameters. Similar findings have been reported [29–30] on the surface roughness of Al-Si alloy with the additions of other elements, wherein the addition of phosphorus to the base alloy has been reported to be beneficial in reducing the surface roughness level and increasing the hardness value. In our work also, the addition of Beryl has dramatically decreased the SR value and enhanced the hardness level. As stated, [31], the obvious reason for the trend obtained in respect of surface roughness after two passes of ECAP may be due to increase in the strain rate resulting in grain boundary sliding, thus yielding smoother surface and superior surface topographical features compared to the annealed samples [32].

3.4 Microscopic Examination

The microscopic examination involved both optical microscopy and scanning electron microscopy, which are covered in detail below.

3.4.1 Light microscopy

The light micrographs pertaining to Al-B-0 AN, Al-B-6 AN, Al-B-0 EP II and Al-B-6 EP II are shown in Figs. 3.4 a & b and 3.5 a & b respectively. From the light micrographs, it is very well seen that the second major element in Al 2024 alloy being Cu alloy shown in these Figs. 3.4 a and b, 3.5 a and b The Al grains, grain boundaries are also marked in the same Figs. 3.4 b and 3.5 b. One can easily make out the differences in the grain sizes by comparing Fig. 3.4 a with Fig. 3.4 b and Fig. 3.5 a with Fig. 3.5 b. There is a gradual reduction in the grain size when the annealed sample undergoes ECAP process with pass I and pass II. In the present work, the number of passes has been restricted to two only in the present work.

The grain size measurements have been carried out using the ASTM standard involving comparison method. Thus, the grain size of Al-B-0 AN, Al-B-6 AN, Al-B-0 EP II and Al-B-6 EP II are 88, 83, 32 and 21 microns, respectively. A similar work done by Mohamed Ibrahim ABD EL AAL and M.M. SADAWY [33] have clearly demonstrated regarding the grain size effect following ECAP in pure Al samples, with increase in number of passes, the grain size reduction has been reported. Thus, the present work gets incredibly good backing from the published work [33]. In another investigation done by Yong Li and T G Langdon [17] ECA pressing of Al 6061 alloy with 10 wt.% Al₂O₃ particles, wherein reduction in the grain size after effecting 5 number of passes has been reported. This work also gives able support to the present finding of ECAP effect in Al Beryl composites. The literature reports [17, 33] and the present work go hand in hand with each other from the point of undergoing grain size decreases during plastic deformation process and its effect on the properties.

3.4.2 Effect of ECAP process on the Tensile properties and Grain size

Figures 3.6, 3.7 and 3.8 present the UTS, %elongation and grain size in respect of Al-B-0 and Al-B-6 samples in the form of bar diagrams.

The plot of tensile strength for the Al 2024 composites containing 0 and 6 wt.% are displayed in Fig. 5, including the ECAP processed samples. From Fig. 3.6, one can make out the fact that with increase in Beryl content from 0 to 6 wt.%, there is an increase in tensile strength to the tune of 56% and 93% in respect of Al-B-0 EP II and Al-B-6 EP II, respectively compared to their corresponding annealed counterparts.

Also, the Al 2024 composites samples undergoing ECAP have clearly indicated much higher level of improvements in the tensile strength both in single and two passes. Also, the tensile strength has become the maximum for ECAP with pass II. When one compares Al-B-0 AN and Al-B-0 EP II with Al-B-6 AN and Al-B-6 EP II, the difference in the grain size is more in Al-B-6 samples, which shows a difference of 54. Whereas the difference is 60 in Al-B-0 samples. This is because in the first instance, ECAP with EP II has reduced the grain size. In the second instance, a further reduction has taken place due to Vander wall/ intermolecular forces acting between the reinforced particles as well as particles to matrix interaction as reported in the literature, its instance in polymer scienc. This type of trends has been explained based on the work done by other researchers [34–35].

As reported [36], Al-Si-Mg composites containing Beryl particles in the range 2 to 10 wt.% have shown hardness increase with increase in Beryl concentration from 0 to 6 wt. % Further, it is reported [36] that the tensile strength has also increased for the Beryl addition up to 6 wt.%, Likewise, many researches have conducted and reported [37] mechanical property evaluations especially hardness and UTS on Al6061 alloy with Beryl as reinforcement particles and obtained increase in hardness and tensile strength with increase in beryl concentration. Thus, all these research contributions [36–37] have given valuable support to the present findings for getting enhanced hardness as well as UTS in Al/Mg alloys/composites containing other types of reinforcements at varied levels.

As regards % elongation effect, it is quite evident from Fig. 3.7 that ECAP has made good influence on the % elongation on the samples. The annealed samples are showing the highest value whereas EP II is exhibiting the least. The other sample namely EP I is showing % elongation value in between them. Further, it is noticed that as the hardness increases, the % elongation decreases. This type of trend is seen in AN, EP I, EP II samples. This is quite logical with the fact that when the hardness increases, the material will tend to become more and more brittle as evidenced from % elongation data as well as from the supporting literature points [38].

Now referring to Fig. 3.8, the AN sample has shown the highest grain size of 89 microns, whereas EP I display the least. This is quite understandable in view of the fact that the samples undergoing plastic deformation involving ECAP with passes I and II, Pass II has revealed substantial reduction in the grain size compared to AN. The sample with EP I is in between these two samples. Thus, the ECAP has played a dominant role in bringing down the grain size to about 21 microns.

3.4.3 SEM for Tensile damage assessment

The fractographic features of tensile damage have been conducted using scanning electron microscopic (SEM) examination.

The SEM images pertaining to Al-B-0 AN, Al-B-6 AN, Al-B-0 EP II and Al-B-6 EP II are enumerated in Figs. 3.9 a and b vs 3.10 a and b respectively. Now comparing Fig. 3.9 b with Fig. 3.9 a, higher degree of plastic deformation with increased matrix distortion and appearance of deep ridges (marked) are seen in Fig. 3.9 a. Further, the debonding and dislocations effects are more pronounced in (Al-B-0 AN) with larger grain boundaries as seen in Fig. 3.9 a compared to Fig. 3.9 b (Al-B-6 AN). Similarly, the samples Al-B-6 AN and Al-B-6 EP II are compared, the samples Al-B-6 EP II (Fig. 3.10 b) reveal less deformation features, finer grain boundaries and less appearance of ridges compared to Al-B-0 EP II (3.10 a) as well as Al-B-6 AN (3.9 b). Also, the matrix distortion and deformation patterns are less noticed in Al-B-6 EP II (Fig. 3.10 b) compared to all the other three samples (Al-B-0 AN, Al-B-6 AN, Al-B-0 EP II). Thus, the SEM examination gives exceptionally good accountability to the damage features, and they are in line with the tensile data gathered in this work. The work may be summarized that the increasing the Beryl addition from 0 to 6 wt.% to the Al 2024 and subjecting it to ECAP, there is a considerable decrease in the grain size and increase in tensile strength. The reason for these trends may be attributed to the plastic deformation involved. The % elongation tries decreases due to the addition of Beryl content of 6 wt.% in Al 2024 alloy. The same explanation holds good for the Al2024 alloy without Beryl addition as well.

The major outcome of the work is detailed below.

The Al Beryl composites have been developed using stir casting route.

The ECAP facility has been designed and developed inhouse involving a suitable die and other associated merchandize required for this purpose.

The porosity trends have decreased drastically in Al-B-6 EP II following ECAP when compared with Al-B-6 AN, Al-B-0 EP II and Al-B-0 AN.

The surface hardness (microhardness) has increased due to ECAP pass II for the Al-Beryl composites. In fact, Al-B-6 EP II has shown the highest hardness compared to all the other samples.

The sample Al-B-6 EP II has exhibited lowest surface roughness in compression with Al-B-6 AN, Al-B-0 EP II and Al-B-0 AN.

Al-B-6 EP II has yielded highest Tensile Strength and least grain size compared to Al-B-6 AN, Al-B-0 EP II and Al-B-0 AN sample.

The Vickers hardness, surface roughness and surface topographical (SEM) features, have been correlated effectively has giving credence to the mechanical data.

The sample Al-B-6 subjected ECAP with 2 passes seen to be the best choice for producing bearing bush components which finds application in automobile industry.

The authors declare no competing interests.

Acknowledgement

The author wishes to acknowledge with inhouse the management of Cambridge Institute of Technology, ACS College of Engineering, Sambhram Institute of Technology, Indian Institute of Science Campus, National Design Research Forum for their valuable support and encouragement in executing the work and preparation of manuscript. The help rendered by Mr. Jitendra Suresh in the preparation of ECAP samples are gratefully acknowledge.

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Effect of Severe Plastic Deformation Involving Ecap of Aluminum 2024 Alloy Beryl Composites on the Mechanical Properties

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Abstract

Figures

1.0 INTRODUCTION

1.1 Plastic Deformation

2.0 Materials and Methods

2.1 Materials

2.2 Methods

2.2.1 Stir Casting

2.2.2 Characterization work

3.0 Results and Discussion

3.1 X-Ray Diffraction Data (XRD)

3.2 Density and Porosity

3.3 ECAP process influencing Surface hardness (SH) and Surface Roughness (SR)

3.4 Microscopic Examination

3.4.1 Light microscopy

3.4.2 Effect of ECAP process on the Tensile properties and Grain size

3.4.3 SEM for Tensile damage assessment

Conclusions

Declarations

References

Status:

Version 1