Electron Backscatter Diffraction Research Articles

Enhancing Mechanical Properties of Cast Ingot Al6061 Alloy Using ECAP Process

AbstractGrain refinement and mechanical property enhancement of cast ingot aluminum 6061 alloy were achieved using equal-channel angular pressing (ECAP) at room temperature, employing route A and route R types. Analytical, finite element and experimental methods were utilized to investigate the alloy’s deformation behavior under the ECAP process. The tensile tests conducted at room temperature demonstrated a significant increase in strength with an increasing number of pressings, reaching 44.23, 53.19, and 56.7% for 1-pass, route A, and route R types 2-passes of the ECAP process, respectively. However, ductility, as indicated by elongation, gradually decreased after the first pressing. Electron backscatter diffraction was employed to reveal submicrometer grain sizes resulting from the ECAP process. The grain structure showed substantial improvement under route A and route R types at a 2-passes ECAP process. Wear tests conducted under loads of 10 and 25 N showed an increase in the coefficient of friction within the minimum wear loss intervals. Rockwell hardness also exhibited a significant increase of 119.3, 176.3, and 164.8% at 1-pass and 2-passes using routes R and A, respectively. As part of the evaluation, analytical models were computed using Python, and finite element simulations were performed using ABAQUS software. The results from analytical and finite element simulations demonstrated good agreement with the experimental data.

Microstructures and wear properties of CoCrFexNi (x = 0, 1) medium-entropy alloy coatings prepared by laser cladding

Purpose High-nitrogen steel is a common material for the manufacture of drilling equipment such as drill collars. However, its poor surface properties often limit its applications. The purpose of this paper is to find a way to enhance the surface performance of high-nitrogen steel, which is expected to improve the wear resistance of high-nitrogen steel. Design/methodology/approach The CoCrNi and CoCrFeNi medium-entropy alloy (MEA) coatings were prepared on high-nitrogen steel substrate by laser cladding technology. The microstructure, phase composition and element distribution of the fabricated coatings were investigated using scanning electronic microscopy, electron backscatter diffraction and X-ray diffraction. The phase structure, phase stability and structural stability of the CoCrNi and CoCrFeNi MEAs were investigated in combination with phase diagram calculation and molecular dynamics. Then the wear tests were carried out for coatings. Findings The results show that both prepared MEA coatings have good quality and contain a single face-centered cubic phase. The wear performance of MEA coatings is improved by the refinement of grain size and the increase of dislocation density. Due to the addition of Fe atoms, the lattice distortion of the CoCrFeNi system increased, resulting in a higher dislocation density of the coating. Cr atoms in the CoCrFeNi system are the largest, and the local lattice distortions induced by them are greater. Through this study, MEA coatings with high hardness can be expanded to drilling field applications. Originality/value CoCrFeNi and CoCrNi MEA coatings were successfully prepared on the surface of high-nitrogen steel for the first time without obvious defects. The micromorphology and grain orientation of the different kinds of coatings were discussed in detail. The hardness-strengthening mechanism and structure stability of the coatings were illustrated by experiments and molecular dynamics simulations. Peer review The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-04-2024-0116/

Effects of different corrugated rolls on the performance of BTW1/Q345R composite plate

Abstract The BTW1/Q345R composite plate not only possesses dual performance advantages of high strength and wear resistance but also contributes to reduced energy consumption and production costs. This paper proposes a novel rolling process based on corrugated rolls for the preparation of wear-resistant steel BTW1/Q345R composite plates.Macroscopic plate shape, microscopic structure, and mechanical properties of the post-rolled wear-resistant steel BTW1/Q345R composite plates are analyzed using techniques such as Electron Backscatter Diffraction (EBSD). The results indicate that the composite plate obtained through rolling with a 3# corrugated roll exhibits a yield strength of 550 MPa, tensile strength of 705 MPa, elongation at break of 17.57%, and shear strength of the composite interface at 242 MPa. Notably, the rolling process with a 3# corrugated roll yields the best combination of tensile mechanical performance and interface bonding performance for the composite plate.

Automated analysis framework of strain partitioning and deformation mechanisms via multimodal fusion and computer vision

Simultaneously investigating strain partitioning and the underlying deformation mechanisms for both the grain interior and the grain boundary (GB) is essential for understanding the complex plastic deformation of hexagonal close-packed metals. To this end, an automated analysis framework based on high-resolution digital image correlation (HRDIC) and electron backscatter diffraction (EBSD) data fusion and computer vision, integrating nanoscale resolution and a large field of view, is proposed. This framework consists of: (1) HRDIC-EBSD data fusion; (2) Segmenting the strain field into individual grains each with a core and a mantle; (3) Data clustering of the Matrix and slip bands (SBs) for each grain; (4) Full slip system (SS) identification and SS assignment to the SBs. The capabilities of this framework were demonstrated on Mg-10Y during compression. The strain field data, which was segmented into different clusters, including grain mantle, grain core, Matrix, and SBs, was analyzed statistically and quantitatively. The pixel-based slip activity, which considers the SB morphology, was obtained from a statistical perspective. Inter-granular accommodating mechanisms, including GB strain, slip transfer, and GB sliding, were quantitatively analyzed. Overall, this analysis framework, which can be applied to other materials, can automatically and statistically evaluate both nanoscale strain fields and underlying intra- and inter-granular deformation mechanisms grain-by-grain. This work provides valuable experimental insights into plastic deformation and accommodation mechanisms for polycrystals.

Simultaneously enhancing the strength and ductility of Fe-Mn-C twinning-induced plasticity steel via Cr/N alloying

The effect of Cr/N alloying on the tensile deformation behavior of Fe-Mn-C twinning-induced plasticity steel was investigated through monotonic tensile tests, X-ray diffraction, electron back-scattered diffraction, transmission electron microscopy, and digital image correlation technique. The results demonstrate that the addition of Cr/N significantly enhances both the strength and ductility of Fe-18Mn-0.6C steel while dynamic strain aging (DSA) behavior weakens or even disappears. Compared with that in the Fe-18Mn-0.6C steel, more densely-spaced, thinner deformation twins were formed in the Cr/N-alloyed steel. Moreover, the Cr/N additions promote deformation twins to form over a wider strain range. This unique twinning behavior leads to a sustained high strain-hardening rate at higher strains, thereby delaying plastic instability and concurrently enhancing strength and ductility.

The Influence of Cu on the Microstructure and Properties of TC4/Q345 High-entropy Joints by Laser Welding

FeCoNiCrCu high-entropy alloy (HEA) and Cu foils were utilized as the intermediate layer to conduct laser welding of TC4 titanium alloy and Q345 steel. Welding is performed by adding single HEA and Cu/HEA double foils as interlayer respectively. We conducted in-depth studies on the microstructure and mechanical properties of the joint by stereomicroscopy, metallographic microscope, scanning electron microscope (SEM), micro-area X-ray diffraction (XRD), nanoindentation, electron backscatter diffraction (EBSD), and tensile testing. The results indicate that the position of the copper foil significantly affects the microstructure and performance of the joint. When the copper foil is on the TC4 side, its lower melting point causes a deeper keyhole, resulting in a narrower weld bead and then reduced content of Fe and Ti in the weld. Simultaneously, the increased proportion of Cu in the weld significantly enhances the content of Cu-rich phases. In the weld zone, we observed freely distributed Cu-rich phases and Ti-rich phases generated along the interface. Under tensile loads, cracks primarily initiate and propagate along the Cu-rich phases, leading to typical delamination on the fracture surface. With the copper foil on the TC4 side, due to the increased copper content in the microstructure, the hardness of the interface between the titanium alloy and the weld decreases, while the joint exhibits the highest tensile strength, reaching a maximum of 417 MPa.

Development and Characterization of a Novel AA6061 Composite Reinforced with Titanium Aluminide via Friction Stir Processing

Current research work emphasizes on the development of particulate titanium aluminide (TiAl), an intermetallic class of material, through mechanical alloying (MA) from elemental powders and usage of same as reinforcement in AA6061 aluminium matrix to enhance its mechanical and tribological performance. TiAl, being a light weight, strong and abrasion-resistant material, is found to be a suitable candidate to replace dense ceramic-based reinforcements in aluminium composite. Friction stir processing (FSP), a well-established surface severe plastic deformation tool, is used to develop the composite in this study. Several strategies on improving the stirring action and particle distribution during FSP is employed and their scientific effect is studied in detail. Microstructural evolution was studied through scanning electron microscopy (SEM) combined with electron backscattered diffraction (EBSD) analysis which revealed uniform particle distribution of reinforcement in the friction stir processed (FSPed) zone with 88.23% reduction in grain size of composite as compared to base material. Hardness studied showed an increase in the hardness by 33% for composite material as compared to un-reinforced FSPed material, showing the positive effect of reinforcement alone on the mechanical strength of the material. Tensile results showed an improvement in yield tensile strength from 156MPa in base to 186.8MPa in the composite material without significant compromise in the ductility 26.86% for composite and 28.14% for base. Mechanisms aiding uniform particle distribution, and the reasons for improvement in mechanical performance of the developed composite is discussed in detail with the help of microstructural studies and post-deformation fractograph.

First widespread occurrence of rare phosphate chladniite in a meteorite, winonaite Graves Nunataks (GRA) 12510: Implications for phosphide–phosphate redox buffered genesis in meteorites

Abstract The first widespread occurrence of rare Na-, Ca-, and Mg, Mn, Fe-bearing phosphate chladniite was observed in meteorite Graves Nunataks (GRA) 12510, which is a primitive achondrite that sits within the winonaite class. Numerous 1–500 µm chladniite grains were found, often on the margins between silicate clasts and the kamacite portions of the large metal veins that permeated through the sample. The largest chladniite grains are associated with merrillite, kamacite, taenite, troilite, albite, forsterite, diopside, and enstatite, with a few tiny chladniite grains and an apatite grain enclosed within merrillite. GRA 12510s average chladniite composition is Na2.7Ca1.25(Mg10.02Mn0.69Fe0.20)Σ10.91(PO4)9. Electron backscattered diffraction (EBSD) patterns indicate varying degrees of nucleation and growth of chladniite grains. Additionally, the first pure Raman spectrum of chladniite is described here, revealing primary ν1 bands at 954, 974, and especially 984 cm–1. The co-occurrence and close association of merrillite, apatite, chladniite, and P-bearing metallic phases within GRA 12510 suggests that the fO2 of IW-2 to IW-4 is an intrinsic property of the precursor chondritic material, and the phosphate-phosphide reaction may have buffered the final winonaite and IAB iron meteorite phase assemblages. Altogether, chladniite appears to form alongside other phosphates, with their chemistries reflecting the diverse environment of their formation. Meteoritic chladniite likely formed through subsolidus oxidation of schreibersite, scavenging Na from albite, Ca from diopside, Mg from enstatite/forsterite, Fe from kamacite/taenite, and Mn from alabandite/chromite when available. A P0-P5+ redox-buffered environment also has implications for thermometry and fast cooling rates, although more experiments are needed to extrapolate powder reaction rates to those of larger crystals. Furthermore, phosphide-phosphate buffered experiments may aid in investigating equilibrium chemistry at fO2 values between IW-2 and IW-4, which have been challenging to explore experimentally due to the limited availability of solid metal-metal oxide buffers between IW (Fe-FeO) and IW-5 (Cr-Cr2O3) at temperatures and pressures relevant to planetary interiors. Future investigations of phosphide-phosphate redox-buffered genesis at fO2 values between IW-2 and IW-4 have important implications for primitive meteorite constituents (e.g., CAI values), partially differentiated planetesimals and planets, including Mercury and core formation on Earth.

Mapping of Microscopic and Local Stress-Strain Curve Information by Combination of Digital Image Correlation and High-Resolution Electron Backscatter Diffraction Methods

Mapping of Microscopic and Local Stress-Strain Curve Information by Combination of Digital Image Correlation and High-Resolution Electron Backscatter Diffraction Methods

Effect of Spherical θ Precipitation in 1.5 GPa Grade Tempered Martensitic Steel on the Occurrence of Delayed Fracture

The objective of this study is to clarify the effect of spherical cementite (θ) precipitation on the occurrence of delayed fracture in 1.5 GPa grade tempered martensitic steels. Constant load tests were performed with a cathodically charged specimen. A 1GPa-load was applied to the specimen, and cathodic charging was performed in 3% NaCl + 3 g/L NH4SCN solution. The specimen of steel without spherical θ did not fracture at the current density of 5 A·m−2 or even by increasing to 50 A·m−2. On the other hand, the specimen of steel with spherical θ fractured after 0.2 h at 5 A·m−2. The strain around the spherical θ after 30%-rolling observed by transmission electron backscatter diffraction showed that the local deformation around the spherical θ was larger than that in the whole measurement field by 3.05 × 1014 m−2 in terms of geometrically necessary dislocation density. In the hydrogen desorption curve by thermal desorption analysis, steel with spherical θ after 30%-rolling showed a larger hydrogen desorption peak around 250 °C than steel without spherical θ. The value of the activation energy of the 250 °C-peak was 109.2 kJ·mol−1. From these results, the 250 °C-peak is inferred to be hydrogen at the disordered interface of θ/tempered martensite. Transmission electron microscopy observation showed cracks and voids on the spherical θ near the delayed fracture surface. These results indicate that the precipitation of spherical θ facilitates the occurrence of delayed fracture. Cracks appear to form around spherical θ.

Strain induced grain growth behavior in laser powder bed fusion fabricated austenitic stainless steel 316L investigated by quasi–in–situ EBSD

A strain induced grain growth behaviour in laser powder bed fusion 316L austenitic stainless steel was investigated in this work. The intrinsic characteristics of the samples, such as crystallographic orientations, dislocation density, low angle grain boundaries and twins, were investigated via quasi–in–situ electron backscatter diffraction. Additionally, grain growth during plastic deformation in samples annealed at 800 °C was attributed to the combined influence of pre–existing twins and strain–induced grain boundary migration.

Clustering and interfacial segregation of radiogenic Pb in a mineral host-inclusion system: Tracing two-stage Pb and trace element mobility in monazite inclusions in rutile

Abstract Accessory minerals like zircon, rutile and monazite are routinely studied to inform about the timing and nature of geological processes. These studies are underpinned by our understanding of the transfer processes of trace elements and the assumption that the isotopic systems remain undisturbed. However, the presence of microstructures or Pb-bearing phases in minerals can lead to the alteration of the Pb isotopic composition. To gain insight into the relationship between Pb isotopic alterations from inclusions and microstructures, this study focused on inclusions from an ultra-high-temperature metamorphic rutile. The studied inclusions are submicrometer monazites, a common mineral rich in Pb but normally not present in rutile. The sample is sourced from Mt. Hardy, Napier Complex, East Antarctica, an ultra-high-temperature (UHT) metamorphic terrane. By applying correlative analytical techniques, including electron backscatter diffraction mapping, transmission electron microscopy (TEM), and atom probe tomography, it is shown that monazite inclusions are often in contact with low-angle boundaries and yield no preferred orientation. TEM analysis shows the monazite core has a mottled texture due to the presence of radiation damage and nanoclusters associated with the radiation damage defects that are rich in U, Pb, and Ca. Some monazites exhibit a core-rim structure. The rim yields clusters composed of Ca- and Li-phosphate that enclose Pb nanoclusters that are only present in small amounts compared to the core, with Pb likely diffused into the rutile-monazite interface. These textures are the result of two stages of Pb mobility. Initial Pb segregation was driven by volume diffusion during UHT metamorphism (2500 Ma). The second stage is a stress-induced recrystallization during exhumation, leading to recrystallization of the monazite rim and trace element transport. The isotopic signature of Pb trapped within the rutile-monazite interface constrains the timing of Pb mobility to ca. 550 Ma.

Additive manufacturing of novel aluminium matrix composites with enhanced strength and processability via boron nitride functionalization

The present work systematically investigates the effects of BN nanopowder functionalization on the processability, microstructure and tensile response of the custom Powder Bed Fusion Laser Beam (PBF-LB) Al alloy ‘AMALLOY3D’. The results show that a minor addition of BN (0.3% by weight) not only produces near fully dense parts (99.91%), but is also paired with improved flowability, enhancing the overall processability. Electron backscatter diffraction (EBSD) analysis revealed the transformation to a fully equiaxed grain structure in the BN-functionalized material, resulting in a 40% increase in yield strength. Energy dispersive spectroscopy using a scanning transmission electron microscope (STEM-EDS) was employed to reveal the intricate secondary phases’ arrangements. These observations coupled with the help of the CALPHAD approach led to the reconstruction of the solidification history of AMALLOY3D and the BN-functionalized material. The present study unravels the complex dynamics leading to the columnar-to-equiaxed transition in BN-reinforced AMCs, proving that such unique microstructures and exceptional tensile properties can be achieved without compromising PBF-LB processability.

Creep Fatigue Interaction at high temperature in C630R ferritic/martensitic heat-resistant steel

The study investigated the creep-fatigue interaction behavior, fracture mechanism, and microstructure evolution of C630R ferritic/martensitic heat-resistant steel at 630 °C and 1% strain amplitude. The results indicate that C630R ferritic/martensitic heat-resistant steel exhibits noticeable cyclic softening behavior, with a decrease in the softening ratio from 0.46 to 0.40 as loading time increases. Microstructure evolution was examined using optical and scanning electron microscopes, revealing the appearance of secondary cracks on the longitudinal section of the sample. These cracks exhibited a curved expansion trend with multiple deformations and highly bifurcated micro-cracks at a low loading time of 30s. However, when the load holding time was increased to 300s, the fatigue cracks tended to expand in a straight line with fewer branches. Furthermore, the observed crack growth path under different loading times showed enrichment in Fe and Cr, with the crack tip containing Cr oxide, which helped prevent fatigue crack propagation. As the loading time increases, the rise in crack closure resulting from oxidation leads to a decrease in crack propagation. Electron backscatter diffraction observation revealed the formation of numerous substructures and recrystallized grains after varying holding times, enhancing the material's resistance to crack propagation. Moreover, the study found that with increasing load dwell time, the deformed grains decreased, and substructural grains became dominant (57.68% and 62.77% under 30s and 300s, respectively). This increased crack resistance resulted in shorter secondary cracks under prolonged load retention, with the secondary crack length decreasing from 146.36μm at 30s loading time to 109.09μm at 300s loading time. Additionally, the kernel misorientation angle value decreased significantly after different loading times, leading to a higher likelihood of cracks or holes forming in regions with high KAM values, where low-angle grain boundaries were formed.

Fatigue Response of Additive-Manufactured 316L Stainless Steel

This study investigated the fatigue performance of 316L stainless steel fabricated via laser powder bed fusion (LPBF). Stress-controlled fatigue tests were performed at different stress amplitudes on vertically built samples using a frequency of 15 Hz and a stress ratio of 0.1. The stress amplitudes were varied to provide the cyclic response of the materials under a range of loading conditions. The average fatigue strength was determined to be 92.94 MPa, corresponding to a maximum stress of 185.87 MPa. The microstructures were observed through scanning electron microscopy (SEM) with the aid of electron backscattered diffraction (EBSD), and the average grain size of the as-built samples was determined to be 15.6 µm, with most grains having a <110> preferred crystallographic orientation. A higher kernel average misorientation value was measured on the deformed surfaces, revealing the increased misorientation of the grains. Defects were observed on the fractured surfaces acting as crack initiators while deflecting the crack propagation paths. The fatigue failure mode for the LPBF 316L samples was ductile, as illustrated by the numerous dimples on fracture surfaces and fatigue striations.

Phase stability and microstructure of neutron-irradiated substoichiometric yttrium dihydrides

The impact of the neutron-displacement damage on phase stability and microstructure of substoichiometric yttrium dihydrides (YHx, x <2) were investigated to assess their use as solid moderator in high-temperature nuclear reactors. YHx specimens were, thus, subjected to neutron irradiations in the range of 0.1–2 displacements per yttrium atom (dpa-Y) in the temperature range of 536–878°C at the Oak Ridge National Laboratory's (ORNL's) High Flux Isotope Reactor (HFIR). YHx specimens were initially prepared at stoichiometry (H/Y) ratios of 1.69 and 1.83. HFIR-irradiated specimens were characterized by variety of techniques to investigate H retention characteristics including dimensional analysis, optical microscopy, scanning electron microscopy electron back scatter diffraction (EBSD), transmission electron microscopy, thermal desorption spectroscopy (TDS), and high-energy x-ray diffraction (HE-XRD) characterizations. Overall, YHx exhibited notable structural and phase stability under short-term neutron-irradiation, except for the samples with significant silicon carbide (SiC) interaction at high doses and temperatures. Basic dimensional and mass measurements were misleading for accurate assessment of H retention, as confirmed by EBSD phase maps, XRD line profiles, and TDS signals. Thus, it was discussed that a robust H retention metric is needed to assess irradiated hydrides. Nanoscale cavities were observed as a result of the neutron irradiation in all samples. Although no clear impact of dose and irradiation temperature was determined, the initial H/Y ratio had an impact on the cavity number density where low H/Y specimens had high-resistance to cavity formation. The Y-vacancy cluster formation at the collision stage of the displacement cascade and their stabilization by H were considered to be the likely underlying mechanisms for the observed cavity microstructure.

Mechanical, Corrosion and Wear Characteristics of Cu-Based Composites Reinforced with Zirconium Diboride Consolidated by SPS

This study aimed to investigate the physical, mechanical, corrosion, and tribological properties of Cu-based composites with varying zirconium diboride content. The composites were successfully consolidated using spark plasma sintering (SPS) at temperatures of 850 °C and 950 °C and a pressure of 35 MPa. The effect of the ZrB2 content and the sintering temperature on the properties of the Cu-based composites was investigated. Scanning electron microscopy (SEM), electron backscatter diffraction (EBSD), and X-ray diffraction were used to analyse microstructure evolution in copper matrix composites. Microhardness tests were used to evaluate mechanical properties. Wear behaviour was evaluated using a ball-on-disc method. Corrosion properties were estimated on electrochemical tests, such as potentiodynamic polarisation. The results demonstrated an enhancement in the density and porosity of the composites as the sintering temperature increased. A uniform dispersion of ZrB2 was observed in the copper matrix for all composites. With an increase in the content of the ZrB2 reinforcement phase, there was an increase in microhardness and an improvement in the wear resistance of the sintered composites. A reduction in densification and corrosion resistance of Cu-based composites was observed with increasing ZrB2 content.

Effect of heat treatment on the deformation behavior of an Al–Cu alloy studied by in-situ synchrotron X-ray diffraction

The effect of T6 heat treatment on microstructure evolution and mechanical properties of a multi-component hot-rolled (HR) Al–Cu alloy were studied by scanning/transmission electron microscopy (SEM/TEM) and electron back scattering diffraction (EBSD), and in-situ synchrotron X-ray diffraction (SXRD). The microstructure in HR alloy comprising Al9FeNi, Al7Cu2Fe, Al3CuNi, Al20Ti2Ce, Al3(TiZr), and Al2Cu; while the HR-T6 alloy containing Al9FeNi and Al7Cu2Fe. The tensile strength and elongation of HR-T6 alloy were improved simultaneously compared to HR alloy. After T6 heat treatment, the tensile strength of sample increased from 240 MPa to 309 MPa (28.75 % improvement) and the elongation increased from 4.1 % to 8.9 % (increased by 117 %). The strain evolution and load partition on behavior of the secondary phase and Al matrix upon tensile load were investigated by in-situ SXRD. The lattice strains of Al matrix and Al9FeNi phase of HR and HR-T6 samples increased from 1750με and 1480με to 2870με and 3490με, respectively, in the plastic deformation zone. The Al matrix and the secondary phase after T6 treatment have improved stress bearing capacity, especially for Al9FeNi phase. The "hard" Al9FeNi phase exhibited higher stress of 377 MPa compared to the "soft" Al matrix (stress of 214 MPa). This work provides an insight into the tailoring of strength-ductility comprehensive understanding the deformation behavior of Al–Cu alloys.

Interface of AlCrTiN/6061 laminated composite fabricated by one-pass rolling and its tribological properties

Inspired by the bionic idea, the AlCrTiN/6061 laminated composite material with “mortar and brick” structure was fabricated by one-pass rolling. And the interface characteristics, dry friction process and wear mechanism of the nacre-like AlCrTiN/6061 laminated composite were systematically studied. Scanning electron microscopy (SEM) confirmed the successful construction of the “mortar-brick” structure in the composite. And high resolution transmission electron microscopy (HRTEM) revealed that Al18Cr2Mg3 phase is formed at the interface of AlCrTiN/6061 laminated composite. Electron back scatter diffraction (EBSD) analysis showed that there are 〈110〉 silk texture in the RD direction. Moreover, the tribological tests indicated that the friction coefficient (COF) of the laminated composites ranged from 0.379 to 0.437, which can meet the requirements of lightweight and high-performance braking of automobiles.

Sustainable recycling of aluminum scraps to recycled aerospace-grade 7075 aluminum alloy sheets

The production of aerospace-grade aluminum alloy sheet is characterized by stringent demands, resulting in a low yield rate. The processing of this material generates considerable amounts of highly alloyed scrap, complicating its recycling due to the challenge of maintaining melt cleanliness. This study employed an aerospace-grade melt refining system to purify the recycled 7075 alloy melt obtained from comprehensive scrap remelting. The melt's cleanliness was assessed using Porous Disc Filtration Analysis (PoDFA) and Liquid Metal Cleanliness Analyzer (LiMCA) and Alscan. The microstructure of the ingots and sheets was examined through Scanning Electron Microscopy (SEM) and Electron Backscatter Diffraction (EBSD), whereas the mechanical properties of recycled sheets were evaluated and benchmarked against those of primary sheet at an aerospace-certified testing facility. The findings indicate that the recycled 7075 sheet meets aviation standards, with no significant differences in microstructure or performance when compared to primary sheet. Furthermore, the study highlights the economic benefits of recycling scrap, revealing a potential cost saving of $4210.8 per ton of recycled sheet. The findings presented herein offer a theoretical framework and empirical evidence supporting the development of a recycling system for aerospace scraps and the certification of airworthiness for recycled aerospace aluminum alloy.