Showing 19 results for Severe Plastic Deformation
Mohammad Mohsen Moshksar, Mohammad Amin Ranaei, Ahmad Afsari, Seyed Yousef Ahmadi,
Volume 14, Issue 15 (3-2015)
Abstract
In this study, commercially pure copper samples were severely deformed by equal channel angular pressing (ECAP) up to 8 passes in room temperature. The effect of sever plastic deformation on the microstructure, mechanical properties, electrical conductivity and electrical wear resistance of the cupper were investigated. In addition, the effect of induced strain on mechanical properties of the extruded cupper in each pass was studied. Field emission scanning electron microscope micrographs show the extreme evaluation of the microstructure after 4 to 8 ECAP passes, in which a large amount of nano and ultra-fine grains are observable. The mechanical properties of the pure cupper in each pass were estimated by compression testing and Brinell hardness method at room temperature. Yield strength and hardness increased by ∼390 MPa and 75HB respectively after 5-pass ECAP due to finer boundary spacing. Increasing the strength of pure copper led to only a minor decrease of the electrical conductivity. Hence, by applying ECAP, one can obtain the ultra-fine pure copper that can improve the mechanical properties without impairing the electrical conductivity. By reducing the applied strain in each pass (25%) of the ECAP process can be obtain the pure copper with higher strength. The electrical wear behavior of the samples was investigated by electrical discharge machining (EDM). The results indicate that, electrical wear of the extruded samples reduces compare to the original samples.
Mostafa Ghadiri, Mahmoud Mosavi, Mahdi Ghamami,
Volume 14, Issue 16 (3-2015)
Abstract
Abstract Various methods have been proposed to produce metallic and bulk form materials.Severe plastic deformation, the ways in which you can set quite a lot of mechanical work applied to the metal. Various methods have been proposed to produce metallic and bulk form materials. However, despite the widespread need for tubes with high strength to weight ratio, few studies and attempts have been done to produce ultra-fine and nano structures.Ultra-fine grain metal created by the process have a high resistance by itself. therefore, these can be as high strength steels are used in harmony with the environment. In this study, optimal design of a cast is done in order to increase the homogeneity of the material microstructure and reduce applied force of the pipe production process.Finite element software is used to design the desired format. Since the framework has been designed based on the pressure in angular channels with parallel tube, the channels angles, corners and curved angles, reshaping and the channel radius ratio, the coefficient of friction between the pipe and the channel and the number of passes are the parameters affecting the process.The effect of the above parameters in a homogeneous effective strain rate and force of the process has been studied.
Abdulrahman Soufi Mohammadi, Mahmoud Mosavi Mashhadi, Ghader Faraji,
Volume 15, Issue 1 (3-2015)
Abstract
This research studies pass numbers effect on microstructure and mechanical properties of magnesium alloy of AZ31C in the tubular channel angular pressing (TCAP) at the temperature of 300 °C. Pressing process has been carried out through four pass over AZ31C Magnesium tubes and in each pass the sample is exposed to Tensile and microhardness test and Metallography. The microstructure and mechanical properties of processed tube through one to four passes of TCAP process were investigated. Microhardness of the processed tube was increased to 62Hv after one pass from an initial value of 55 Hv. An increase in the number of passes from 1 to higher number of passes has not more effect on the microhardness. Yield and ultimate strengths were increased 1.97 and 1.49 times compared to as cast condition. Notably increase in the strength was achieved after two pass TCAP while higher number of passes has not more effect. Microstructural investigation shows notably decrease in the grain size to around 6 µm from the primary value of ~200 µm. microscope images show that the grain size is getting smaller by the first pass buy bigger in the next passes.
Hesam Torabzadeh Kashi, Ghader Faraji,
Volume 15, Issue 8 (10-2015)
Abstract
In this research, a novel severe plastic deformation (SPD) method entitled cyclic flaring and sinking (CFS) is presented for producing of the ultrafine-grained (UFG) thin-walled cylindrical tubes. Finite element (FE) results showed that CFS process has a good strain homogeneity and requiring a low load. CFS process includes two different flaring and sinking half-cycles. At flaring half cycle, the flaring punch with two stepped regions is pressed into the tube. Shear and normal tensile strains are applied as a result of the existence of shear zones and increase in the tube diameter. In the second half cycle, the tube is then pressed to sinking die that applies same shear strains and normal compression strain so that the initial diameter of the tube is achieved and high plastic strain is applied. This process can be run periodically on the tube to exert more strain and consequently finer grain size and ultimately achieve better mechanical properties. The results indicated that the yield and ultimate strengths of the CFS processed Al (1050) tube were significantly increased to 165 MPa, and 173 MPa, respectively from the initial values of 50 MPa, and 115 MPa. The elongation to failure was decreased to about 14% after three cycles from the initial value of 42%. In addition, the hardness increases to ~38 Hv after ten cycles of CFS from ~23 Hv. Keywords
Soheil Nakhodchi, Mohammad Mahmoudi, Ali Shokuhfar,
Volume 16, Issue 4 (6-2016)
Abstract
Combined shear extrusion (CSE) is a new severe plastic deformation (SPD) technique to produce bulk ultra-fine grained materials. CSE is obtained by the combination of simple and pure shear extrusion. This technique is based on definitions of pure and simple shear. In the present work, the nonlinear (large) deformation elasticity theory is used for obtaining the shear strain applied to the sample under pure shear extrusion with various angles of distortion. Also plastic deformation characteristics of CSE method were analyzed with finite element analysis using commercial Deform 3D software. Shear strain and effective strain applied to the sample, the load required to carry out the process and the final shape of the cross-sectional area were studied for different angles of distortion. Analytical results and finite element analysis shows by increasing the angles of distortion, shear strain and increased rate of shear strain applied to the sample increased so the effective strain and load required to carry out the process increases. Analysis of finite element and geometry of the die shows that distribution of shear strain and effective strain is inhomogeneously and symmetrical in specimen’s cross section which increases from the center to the corners and by increasing the angles of distortion, distribution of strain becomes more inhomogeneously, also the final shape of the cross-sectional area deforms more.
Mahmoud Shamsborhan, Mahmoud Moradi, Ali Shokuhfar,
Volume 16, Issue 5 (7-2016)
Abstract
The most successful ‘‘top–down’’ approach to produce bulk ultra-fine grained or nanostructured materials involves the use of severe plastic deformation (SPD) processing. The amount of higher effective plastic strain per pass plays a key role on the final microstructure of SPD processed samples. In the present study the numerical experiments of the combination of the equal channel angular pressing (ECAP) and simple shear extrusion (SSE) as a new process entitled “planar twist channel angular extrusion (PTCAE)” was performed based on the Response Surface Methodology (RSM), as a statistical design of experiment approach, in order to investigate the effect of parameters on the response variations, achieving the mathematical equations, predicting the results to impose higher effective plastic strain values. Α and ϕ angles, radius and friction coefficient was imposed as the input parameters while average, minimum and maximum effective strain and maximum load was imposed as the output parameters. Governing regression equations obtained after analysis of the simulation data by Minitab software. Optimum process parameters are: α=450, Φ =450, r=2 mm and µ=0.1. Verification of the optimum results using simulation experiment was done. Good agreement between simulation, experimental and optimization was occurred.
Hessam Torabzadeh, Ghader Faraji,
Volume 16, Issue 6 (8-2016)
Abstract
In this article, it is tried to be mentioned the functional structure of production methods of ultrafine-grained (UFG) and nanograined tubes. As well as metallurgical and mechanical effects of these methods on the matter are fully investigated. Ultrafine grained materials contain grains with an average size of 100-1000 nm and if the grain size is less than 100 nm, the material is classified as nanograined material which have a lot of applications in different industries such as aerospace, automobile, military and medical. Generally, the methods presented in this paper has been done on common materials like aluminum and pure copper and magnesium alloy AZ91. Extremely large plastic deformations lead to ultrafine-grain or nearly nanomaterial in the severe plastic deformation (SPD) methods. Most severe plastic deformation methods for producing ultra-fine grain bulk, whereas in the past decade due to the increasing need tube components with high strength and good ductility, The research was conducted to produce UFG tubes. Advances in this field presented formally so that the advantages and disadvantages of each process are clearly comparable. The most important advantage of ultrafine-grain materials is an enhanced mechanical strength in comparison with their coarse grain counterparts. The microstructural reasons are discussed. Furthermore, this article reviews the refinement and deformation mechanisms, e.g. dislocation deformation mechanism, twin deformation mechanism, grain boundary sliding etc. of SPD methods.
Behzad Binesh, Mehrdad Aghaie-Khafri, Mohammad Daneshi,
Volume 17, Issue 8 (10-2017)
Abstract
In this study, severe plastic deformation of 7075 aluminum alloy was investigated using a new method, based on the combination of conventional upsetting and direct extrusion. In this process, which is called repetitive upsetting-extrusion, cylindrical samples were first subjected to upsetting and were subsequently subjected to extrusion at 250 °C with various processing cycles. Die design was carried out considering the possibility of conducting both upsetting and extrusion by using a single die and the maximum of four RUE cycles were successfully performed on the samples. Finite element method was used to simulate the deformation behavior of 7075 alloy during repetitive upsetting-extrusion processing and the strain distribution was obtained for the deformed samples. The finite element simulation results correlated fairly well with the microstructural observations. Based on the simulation results, the maximum effective strain was observed at the central region of the samples. The deformation behavior and the flow pattern were discussed based on the experimental and the simulation results. In addition, the effect of applied strain on mechanical properties of processed samples was studied. Tensile strength and elongation of deformed samples increased with extending the number of repetitive upsetting-extrusion cycles.
Ali Fata, M Eftekhari, Ghader Faraji, M Mosavi,
Volume 17, Issue 12 (2-2018)
Abstract
In this study, the effect of Parallel tubular channel angular pressing (PTCAP) as a severe plastic deformation (SPD) process on the microstructural, mechanical properties and superplasticity of AZ31 magnesium alloy were investigated. PTCAP method at 300°C was performed for production of ultra-fine grained (UFG) tube with a high superplasticity. After the first pass of PTCAP a bimodal microstructure, large gains surrounded by a large number of tiny recrystallized ones, was observed. The grain refinement and homogeneity of the microstructure increased by applying subsequent passes of PTCAP. After four pass of PTCAP, the average grain size of the material decreased from 43 µm to 6.8 µm. Vickers microhardness measurements revealed that by applying more PTCAP passes and consequently, more grain refinement, the value of hardness increased. Fractographic SEM images showed that predominately ductile fracture was occurred in all hot tensile specimens. A higher elongation to failure of 256% was achieved at a higher tensile testing temperature of 450°C and a strain rate of 10-3 1/s, due to grain boundary sliding as a dominant deformation mechanism, while this values for the as-received sample is 116% at the same tensile testing condition. Finally, it was observed that the four-pass PTCAP processed sample has higher room temperature microstructural and mechanical properties and also higher elevated temperature superplasticity than the as-received sample. Also, the grains thermal stability test was done on the four-pass PTCAP processed sample at 5 different temperatures.
M. Eftekhari, Ali Fata, , M. Mosavi,
Volume 18, Issue 5 (9-2018)
Abstract
The main goal of this study is achieving thin-walled AZ31 magnesium alloy tubes with high ductility at elevated temperature. For this purpose, a combined severe plastic deformation method, including parallel tubular channel angular pressing (PTCAP) and tube backward extrusion (TBE) was used. First, PTCAP process was applied on tubular samples at 300°C and then, TBE process was performed at 300°C. After PTCAP, a necklace like microstructure, large gains surrounded by a large number of tiny recrystallized ones, was observed and the average grain size of the material decreased from 520 µm to 11.1 µm. At the next stage, After TBE, an ultra-fine grain microstructure with an average grain size of 8.6 µm was formed. After performing this combined method, the hardness value of the PTCAP and TBE processed sample increased from 37 HV to 69 HV. Hot tensile testing studies at 300°C revealed an elongation to failure value of 181% for the PTCAP and TBE processed sample, while this value for as-received sample was 55%. Fractographic SEM images showed that predominately ductile fracture was occurred in all hot tensile specimens due to nucleation of microvoids and their subsequent growth and coalescence with each other.
M. Eftekhari, Ali Fata, , M. Mosavi,
Volume 18, Issue 5 (9-2018)
Abstract
The main goal of this study is achieving thin-walled AZ31 magnesium alloy tubes with high ductility at elevated temperature. For this purpose, a combined severe plastic deformation method, including parallel tubular channel angular pressing (PTCAP) and tube backward extrusion (TBE) was used. First, PTCAP process was applied on tubular samples at 300°C and then, TBE process was performed at 300°C. After PTCAP, a necklace like microstructure, large gains surrounded by a large number of tiny recrystallized ones, was observed and the average grain size of the material decreased from 520 µm to 11.1 µm. At the next stage, After TBE, an ultra-fine grain microstructure with an average grain size of 8.6 µm was formed. After performing this combined method, the hardness value of the PTCAP and TBE processed sample increased from 37 HV to 69 HV. Hot tensile testing studies at 300°C revealed an elongation to failure value of 181% for the PTCAP and TBE processed sample, while this value for as-received sample was 55%. Fractographic SEM images showed that predominately ductile fracture was occurred in all hot tensile specimens due to nucleation of microvoids and their subsequent growth and coalescence with each other.
H. Salari, M. Mahmoodi, E. Borhani,
Volume 19, Issue 9 (9-2019)
Abstract
The cold roll bonding (CRB) is a type of bonding process between similar and/or dissimilar metals that is bonded through plastic deformation via rolling process at room temperature. In addition, the accumulative roll bonding (ARB) process is considered as one of the methods for applying severe plastic deformation (SPD) with the ability to achieve ultra-fine grains (UFG) structure and improved mechanical properties. In this research, a combined method was suggested consisting of ARB and CRB processes in order to fabricate UFG copper strip with simultaneous increase of strength and electrical conductivity. Microstructure, mechanical properties, and electrical conductivity of copper specimen fabricated via combined method and ARB processes were investigated. Field emission scanning electron microscope (FESEM) micrographs showed in the crystalline structure of the specimen fabricated via combined method, a large amount of the UFG with uniform distribution are observable. Also tensile strength and hardness of strips increased with increasing the number of rolling passes. Finally, investigation the electrical conductivity of the specimens by four-point probes test showed electrical conductivity decreases with increasing the number of ARB cycles, while the specimen fabricated via combined method increased simultaneously strength, hardness, and high electrical conductivity.
S.m. Ghalehbandi , A. Fallahi, H. Hosseini Tudeshki ,
Volume 20, Issue 2 (1-2020)
Abstract
The focus of this paper is to investigate the possibility of consideration of grains and grain boundaries and their elastic-plastic behavior to predict the stress-strain behavior of ECAPed 7075 Al alloy using a finite element micromechanical approach. For this purpose equal channel angular pressing is performed on the alloy and hardness and tensile tests were performed in the macro mode as well as the micro-indentation test on distinct areas of microstructure. Mathematical relations were obtained for the correlate the hardness and static strength properties of the alloy using the obtained data from hardness and tensile tests. In addition to the mathematical relations, backward simulation of the micro-indentation process has been used in the Abaqus finite element software to convert the hardness in the grain and its boundary to stress-strain curves. The elastic-plastic behavior of the phases has been used in microstructural modeling. Modeling of the strain test has been performed in the finite element software for the microstructures using the microstructural image. The predicted stress-strain behavior from microstructural modeling has been compared with experimental results.
A. Siahsarani , Gh. Faraji, F. Samadpour,
Volume 20, Issue 4 (4-2020)
Abstract
Magnesium and its alloys have received much attention not only in the aerospace and electronics industry, but also in medical applications due to its low density, excellent physical properties, and biocompatibility. However, magnesium and its alloys have low ductility and poor strain hardening ability because of the hexagonal crystal structure with the limited number of slip systems at room temperature. Therefore, it seems necessary to improve their ductility and other mechanical properties via novel technologies. In this research, hydrostatic cyclic expansion extrusion has been used to produce ultrafine-grained magnesium rod. Properties of produced rods have been investigated morphologically and mechanically. The numerical investigation has also been performed to show the effects of hydrostatic pressure on strain distribution. Due to the brittleness of magnesium, the process has been conducted at elevated temperatures. Also, due to the fluid limitation at high temperatures, melted polyethylene has been used as the fluid in the process. The results showed that the yield and ultimate strength increased by 54% and 43% after only one pass of the hydrostatic cyclic expansion extrusion process, respectively. Also, elongation increased by 46%. Furthermore, microhardness has also increased with an average of 57 Hv to 70 Hv. The microstructure result showed that the grains become ultrafine-grained after only one pass of the process. Finite element investigation revealed that high hydrostatic pressure has a good effect on improving the strain distribution and the microstructure. This process seems very appropriate for industrial applications due to its ability to produce long ultrafine-grained rods.
M. Motallebi Savarabadi , Gh. Faraji, M. Eftekhari,
Volume 20, Issue 4 (4-2020)
Abstract
Hydrostatic tube cyclic expansion extrusion process is a newly invented severe plastic deformation technique for producing long ultrafine-grained and nanostructured tubes with higher mechanical properties. In the present research, this process was applied through two passes at room temperature on the commercial purity copper. Then, the hardness, tensile properties, fracture surface and microstructure of the samples were evaluated. The main goal of this research was to achieve a material with a simultaneous high strength and desirable ductility. In this process, the utilization of pressurized fluid between the die and the tube leads to first, the desired improvement of mechanical properties due to the effects of hydrostatic compressive stress. Second, the reduction of a required deforming force
to eliminating the friction between the die and the tube leads to the facilitation of producing relatively long ultrafine-grained and nanostructured tubes. After two passes of process, a nearly equiaxed and homogeneous ultrafine-grained (UFG) microstructure was observed. The yield strength and ultimate strength increased from 75 MPa and 207 MPa to 310 MPa and 386 MPa, respectively. However, elongation to failure decreased from 55% to 37%. Also, the hardness value of the tube increased significantly from 59 Hv to 143 Hv, and the uniform distribution of hardness was obtained through the thickness of the tube. The fractography evaluations revealed that the predominantly ductile fracture happened in all samples of tensile testing. The hydrostatic tube cyclic expansion extrusion process can be utilized as a practical industrial method for producing relatively long ultrafine-grained tubes.
M. Baghinipour, F. Biglari,
Volume 20, Issue 6 (6-2020)
Abstract
Fine grain materials exhibit excellent mechanical properties and are widely used in various industries. One way to produce fine grain bar is by using the severe plastic deformation techniques. Cyclic extrusion and expansion of the sample is used as one of the methods of severe plastic deformation for production of fine-grained bars. As the length of piece increases, the friction force increases, so that the required force for shaping operation is increased to such an extent that the process cannot be performed. For solving this problem, the "Cyclic Extrusion and Expansion under Hydrostatic Pressure" is proposed as a new method of severe plastic deformation for production of long-length fine-grained bars. In this method, the forming operation was done by using a pressure oil, so the hydrostatic compressive stresses are applying to the material and improve the mechanical properties. Also, the results of simulation of finite elements of this method show the effect of friction coefficient on the forming force and independence of the forming force from the bar length due to the hydrostatic process. Therefor the process is capable of producing rods of long length and fine structure. Results of pure copper rebar underwent this process showing that the yield strength and final strength increased by 200% and 33%, respectively. Also, the sample hardness increased substantially by 120%, and the distribution of relatively homogeneous hardness in rebar diameter was obtained. The microstructure results showed a fine-grain after the process, with the grain size reduced to 8μm in center and 5μm in outer diameter.
Davood Yousefi, Reza Taghiabadi, M.h. Shaeri,
Volume 21, Issue 10 (10-2021)
Abstract
In this study, the effect of multidirectional forging (MDF) was studied on the microstructure and mechanical properties of Ti-modified SiP/ZA22 composite containing 4 and 8 wt. % Si. The forging process was performed at 100 °C by two and five passes. Based on the obtained results, Ti modification refined the coarse primary dendrites, and reduced the size of primary Si (SiP) particle as well as grains. Applying MDF also gradually eliminated the dendritic structure, promoted fine distribution of SiP particles, second phases, and porosities in the microstructure. According to the image analysis results, the average size of SiP particles in as-cast composite reduced from 25 and 30 μm to about 6 and 7 μm, respectively in 5-pass MDFed composites containing 4 and 8 wt. % Si. The mechanical properties results also showed work softening during the MDF where after two-pass MDF the hardness and tensile strength of the base sample reduced by 30 and 25%, while its elongation and toughness improved by 120 and 325%, respectively. In MDFed composites, the presence of SiP particles maintains the hardness and strength. According to the results, in the case of 2-pass MDFed composite containing 4 wt. % Si the hardness and tensile strength reduced by 18 and 2%, respectively, but the elongation and toughness increased by 25 and 175%, respectively.
Mohammad Eftekhari, Ghader Faraji, Mostafa Bahrami,
Volume 21, Issue 10 (10-2021)
Abstract
In present study, hydrostatic tube cyclic extrusion compression process is introduced as a novel severe plastic deformation process for grain refining and improving mechanical properties of tubular components. Also, this process has the potential to produce relatively long and large tubes. In this process, because of the utilization of pressurized hydraulic fluid between the tube and die, there is nearly no contact friction. This leads to a significant reduction in pressing load. In this research, after applying hydrostatic tube cyclic extrusion compression process on pure copper tube, the microstructure evolution and the mechanical properties improvement were examined. The results denoted that this process was successfully performed on pure copper tube. In this way, the microstructure and mechanical properties were improved significantly. For example, after this process, the ultimate strength of pure copper, the yield strength and the value of hardness became 1.57, 1.85 and 1.86 times higher, respectively, and a low loss of ductility was achieved. Also, after this process, an ultrafine cellular microstructure with average size of about 990 nm were observed. While, the average value of grain size for the unprocessed tube was about 40 μm. The stages of the formation of the observed microstructure are as follows: the creation of a high density of dislocations, the dislocations coalescence with each other and the formation of tangled structures, the formation of ordered arrangements of dislocations and low angle boundaries, the formation of dislocation cells to diminish strain energy, the creation of new dislocations and their movement to boundaries.
Milad Aali, Mohammad Eftekhari, Ghader Faraji,
Volume 23, Issue 9 (9-2023)
Abstract
In present study, an improved severe plastic deformation process named improved tube cyclic expansion extrusion process has been introduced. The idea of this process is taken from the conventional tube cyclic expansion extrusion process, and in this novel process, it is tried to solve some important problems of the conventional process. Improved tube cyclic expansion extrusion process is capable of severe plastic deforming and improving microstructure and mechanical properties of tubular components. Also, this process can be considered for producing relatively long tubes. For this purpose, the improved tube cyclic expansion extrusion process was successfully performed on AZ91 magnesium alloy tubes, up to two passes. Then, the microstructure evolution and the mechanical properties improvement were scrutinized. The results showed that the microstructure and mechanical properties were improved considerably. In this way, after two passes of this process, an ultrafine grained (UFG) microstructure was formed, and the values of ultimate strength (UTS), hardness (Hv) and ductility (EL%) became 3.6, 1.83 and 1.8 times higher, respectively. Also, the comparison of the results of the improved tube cyclic expansion extrusion process with those of the conventional tube cyclic expansion extrusion process indicated that ultimate strength and hardness of the improved process were near to those of the conventional process, but the value of elongation to failure of the improved process is considerably higher than the value of the conventional process. This can be considered as one of the important advantages of the improved process over the conventional process.
