Numerical analysis of back pressure equal channel angular pressing of an Al-Mg alloy

Abstract

Ultrafine grain size provides enhanced mechanical and/or physical properties such as strength and high ductility, superplasticity at relatively low temperatures and high strain rate and better corrosion resistance. Well-known as one of the most promising and effective structure refining method among other severe plastic deformation (SPD) techniques, equal channel angular pressing (ECAP) has been intensively investigated due to spectacular improvements in structure and therefore properties of bulk ultrafine grained/nanostructured materials. A successful ECAP requires surpassing two obstacles: the necessary load level which directly affects tools and a favourable stress distribution so the material withstanding the accumulated strain of repeated deformation. Materials could withstand more passes if a back pressure (BP) is applied. In traditional ECAP, tensile stress along the contact surface between the work piece and the upper wall of the outlet channel leads to crack initiation, while in the presence of BP, a negative (compressive) stress appears during the process balancing the tensile stress. In this study a comparative tridimensional finite element analysis (FEA) is performed to evaluate the flow of an Al-Mg alloy depending on different BP levels and process parameters. The results in terms of load level and strain distribution show the influence of BP on the material behaviour, opening opportunities for industrial applications.