Flow stress recovery experiments were performed on polycrystalline high purity aluminum following room temperature tensile prestrains of 5%, 10%, 15%, 20% and 25%. Isothermal recovery temperatures of 120, 160 and 200°C were used for recovery times up to 300 h. It was found that work hardening at room temperature is accompanied by the development of dislocation tangles that form the boundaries of a dislocation cell structure. These tangles were found to develop along {100},{110} and {111} planes. The cells formed decrease in size with increasing strain up to 15%, thereafter remaining constant at an average size of about 1.8 μm. The cell structure converts to a sharply defined subgrain structure during recovery as the tangles are rearranged into networks. The network planes are the same as those on which the original tangles were formed. During recovery following tensile prestrains less than about 15%, the subgrain size tends to grow by two mechanisms: (1) subgrain coalescence and (2) subboundary coalescence. The flow stress related to formation of dislocation substructures has been found to be inversely proportional to either the cell or the subgrain size for prestrains less than 15%, where the dislocation density in, and the misorientation angle of, the cell or subgrain boundaries was found to be nearly constant. In this region, conversion from cell to subgrain by recovery annealing results in a 24% loss of flow stress, independent of the prestrain used. Above about 15% tensile prestrain, the flow stress continues to rise without a significant decrease in the cell or subgrain size but with an increase in the density of dislocations in the cell walls and the average misorientation angle of the subboundaries. Furthermore, the subgrains formed after strains greater than 15% are more thermally stable, i.e. they do not grow appreciably during recovery annealing for 300 h at a temperature of 160°C.
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