Preparation of Ultrafine-Grained Continuous Chips by Cryogenic Large Strain Machining

Haitao Chen,Wenjun Deng,Jiayang Zhang,Baoyu Zhang

doi:10.3390/met10030398

Abstract

Conventional orthogonal machining is an effective severe plastic deformation (SPD) method to fabricate ultrafine-grained (UFG) materials. However, UFG materials produced by room temperature-free machining (RT-FM) are prone to dynamic recovery, which decreases the mechanical properties of UFG materials. In this study, the cryogenic orthogonal machining technique was implemented to fabricate chips that have an abundant UFG microstructure. Solution-treated Al-7075 bulk has been processed in cryogenic temperature (CT) and room temperature (RT) with various machining parameters, respectively. The microstructure, chip morphology and mechanical properties of CT and RT samples have been investigated. CT samples can reach a microhardness of 167.46 Hv, and the hardness of CT samples is higher than that of the corresponding RT samples among all parameters, with an average difference of 5.62 Hv. Piecemeal chip obtained under RT has cracks on its free surface, and elevated temperature aggravates crack growth, whereas all CT samples possess smoother surfaces and continuous shape. CT suppresses dynamic recovery effectively to form a heavier deformation microstructure, and with a higher dislocation density in CT samples, they further improve the chips’ hardness. Also, CT inhibits the formation of solute cluster and precipitation to enhance the formability of material, so that continuous chips are formed.

Highlights

Nanostructured Al 7XXX Series alloys, based on the Al–Zn–Mg–Cu system of nanocrystalline (NC)and ultra-fine grained (UFG) structures, have drawn attention because of their exceptional mechanical properties [1]
The morphology of produced chips at different machining speeds with a 10◦ rake angle is expressed in Figure 3, the chips’ shape, which was produced at low velocities is discontinuous and curly, due to the chip formation mechanism being in the Built-Up Edge (BUE) mode
As the cutting speed increased to approximately 953 mm/s, continuous ribbon and enlarge bending radius chips which embody flatter morphology were formed under cryogenic temperature (CT), but pronounced crack and fragile block chips appear under room temperature (RT)

Summary

Introduction

Nanostructured Al 7XXX Series alloys, based on the Al–Zn–Mg–Cu system of nanocrystalline (NC)and ultra-fine grained (UFG) structures, have drawn attention because of their exceptional mechanical properties [1]. Severe plastic deformation (SPD) methods, such as accumulative roll bonding (ARB) [2], equal channel angular pressing (ECAP) [3], high-pressure torsion (HPT) [4] and large strain extrusion machining (LSEM) [5,6,7], have been used for achieving microstructure refinement in metals and alloys. These SPD methods have a few disadvantages and limitations.

Methods

Results

Conclusion