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Introduction
The need for materials of high strength and low density (i.e.
having high specific strength) in aerospace applications has
led to the development of several aluminium alloys. While
alloying, heat treatment, and mechanical working are
known to improve the strength of aluminium alloys, the
procedure is usually accompanied by a significant loss in
ductility. This limits the formability of high strength
aluminium alloys. In fact, most of the commercially
promising aluminium alloys are known to exhibit much
lower ductility than that of aluminium at ambient
temperature. However, after suitable thermomechanical
processing, several commercial aluminium alloys can be
made superplastic, whereby they exhibit tensile ductility
exceeding several hundred per cent. One aluminium alloy to
have attracted a large number of research activities leading
to successful implementation of superplasticity in aerospace
applications in the past decade is AA 8090 Al Li alloy.
This alloy has been extensively studied to characterise
superplastic flow in terms of strain rate sensitivity index and
ductility,1,2 mechanisms for superplastic flow,3,4 superplastic formability,5 and texture evolution.6 8
Lloyd1 and Ridley et al.2 reported maximum ductility to
be associated with maximum values of strain rate sensitivity
.
index m at intermediate strain rates e and elevated
1
temperatures T. While Lloyd found the maximum ductility
.
to be 640% at e~1.761024 s21 and T~753 K, Ridley et al.2
pointed out that concurrent grain growth during superplastic deformation shifted the strain rate for maximum
ductility and m towards a lower value. The adverse effect of
concomitant grain growth on ductility, however, could be
compensated by performing tensile tests at a constant
crosshead speed (constant initial strain rate) instead of at a
constant true strain rate, whereby the strain rate automatically decreases with increasing strain. The constant
crosshead speed type tests at 793 K thus led to a maximum
ductility of more than 850% with an initial strain rate of
y161024 s21. In constant true strain rate tests, such grain
growth is also responsible for an apparent increase in flow
ISSN 0267 0836
431
432 Fan et al. Effects of strain rate and temperature on flow and microstructure of AA 8090
Results
Experimental procedure
The superplastic forming (SPF) grade of Al Li alloy of
composition (wt-%) Al 2.5Li 1.4Cu 1.2Mg 0.11Zr was
obtained from Alcan in the form of a sheet 1.8 mm in
thickness. Tensile specimens of 10 mm gauge length and
5 mm gauge width were machined, with the tensile axis
being kept parallel to the rolling direction. True constant
strain rate tensile tests were carried out with a computerised
Instron universal testing machine. Test temperatures were
controlled to an accuracy of 1 K. Before straining the
specimens, 20 min was allocated for heating to and soaking
at the test temperatures. After deformation, the specimens
were rapidly quenched within 100 ms using a specially
designed in situ quenching facility.9
Metallographic specimens were mechanically polished.
Etching was done with Kellers reagent, comprising 1%HF,
1.5%HCl, and 2.5%HNO3 in water. Grain size was
measured in the longitudinal section by the mean linear
incept method. This was carried out manually during
examination of the microstructure using a Leitz TAS plus
image analyser. Orientation image microscopy (OIM) was
carried out on the longitudinal surface using a TSL
orientation image microscope attached to a Jeol 840
scanning electron microscope. For this, the specimens
b
a rolling; b midlongitudinal
Fan et al. Effects of strain rate and temperature on flow and microstructure of AA 8090 433
(a)
(b)
(a)
.
.
a e~161023 s21; b e~161024 s21
3 True stress true strain curves at various test temperatures ranging from room temperature to 843 K
FLOW BEHAVIOUR
Individual tensile specimens were deformed to failure in the
temperature range 298 843 K at the constant strain rates
161023 s21 and 161024 s21. The resulting stress strain
curves at these two strain rates are plotted in Fig. 3. As
expected, the flow stress increases with a decrease in test
temperature. Figure 3 also indicates a decrease in elongation to failure and an increase in flow hardening rate with a
decrease in test temperature. At higher test temperatures of
773 K and above, the s e curves suggest that a steady state
of flow stress has been attained, whereby the stress no
longer varies as a function of strain. The transitional flow
behaviour, beyond which the flow stress becomes independent of strain, appears to extend to a larger strain level as
the strain rate of deformation is increased.
The flow stresses at various temperatures were normalised (s/E) by Youngs moduli E at the corresponding
temperatures, according to the work of Pu et al.,4 and were
plotted as a function of homologous temperature T/Tm,
where Tm is the absolute melting point, at the fixed strain
levels. As shown in Fig. 4, at the onset of plastic strain, the
decrease in flow stress with increasing temperature was
found to be less sensitive to temperature towards the lower
and upper ends of the temperature range investigated. At all
(b)
a T~623 K; b T~803 K
434 Fan et al. Effects of strain rate and temperature on flow and microstructure of AA 8090
(a)
(b)
MICROSTRUCTURAL EVOLUTION
To investigate microstructural evolution, metallographic,
TEM, and OIM specimens were prepared from the gauge
and shoulder sections of the tensile specimens after
deformation to various strain levels. Also included were
those specimens obtained by heating to and soaking at the
test temperatures, before straining. Grain growth, evolution
of the midthickness elongated grains into equiaxed grains,
cavitation, dislocation interactions, texture evolution, and
the transformation of low angle boundaries into high angle
boundaries were observed. While some of these features
were quantified, others were evaluated only qualitatively.
Described below are some of the typical microstructural
observations made in the present study.
Grain growth
Grain growth, cavitation, and transformation from elongated grains into equiaxed grains are illustrated in Fig. 9
(cf. Fig. 1). The micrographs of longitudinal sections of the
tensile specimens shown in Fig. 9 represent the microstructures developed upon deformation to varying strain
levels, under the temperature and strain rate condition of
803 K and 161023 s21. After deformation to a large strain,
the microstructure became more or less uniform on all three
mutually perpendicular surfaces (Fig. 10).
Grain growth that occurred at the various test temperatures is plotted in Fig. 11, which shows the grain size results
Fan et al. Effects of strain rate and temperature on flow and microstructure of AA 8090 435
9 Microstructures of longitudinal sections illustrating grain growth, change from elongated grains to equiaxed grains,
and cavitation with progress in superplastic deformation at temperature of 803 K and strain rate of 161023 s21
10 Three-dimensional
microstructure
of
specimen
deformed to e~1.75 at temperature of 803 K and
23 21
strain rate of 1610 s
436 Fan et al. Effects of strain rate and temperature on flow and microstructure of AA 8090
: :
: (1)
Substructural evolution
Transmission electron microscopy was carried out on the
tensile specimens deformed to e~0.5 at the strain rate of
161023 s21 and at constant test temperatures of 623, 723,
803, and 843 K. For this, thin foils of the midthickness layer
were prepared, and they were examined in the normal
direction of the original sheet. Three examples are shown in
Fig. 13 to illustrate the effect of test temperature on the
deformed substructures. At 623 K, T2, b9, silicon rich, and
iron rich phases were found to be prevalent (Fig. 13a).
However, at higher test temperatures of 773 K and above,
T2 was found to have dissolved but b9, silicon rich, and iron
rich phases were still present (Fig. 13b and c). Figure 13
shows evidence of dislocation activities during superplastic
deformation. However, it remains to be examined whether
the appearance of dislocations is enhanced by the presence
of precipitates or some thermal contraction associated with
the fast rate of cooling. The extent of contraction can be
evaluated from the following analysis. The coefficient
of thermal expansion for aluminium is 23.661026 K21
and the cooling rate to freeze the substructure was
y1273 K s21. This can introduce a compressive strain
(despite being physically unloaded upon completion of
tensile tests) at a strain rate of y361022 s21. For the test
temperature of 843 K, for example, the compressive strain
can be substantial (ey20.019) and can influence the prior
dislocation structures.
Texture evolution
Tensile specimens were deformed to selected strain levels at
.
T~803 K and e~161023 s21, to follow the texture
evolution. Some of the results have been presented earlier.10
Table 1 Values of K and
. n of equation (1) at various test
temperatures: e~161023 s21
T, K
K, mm
723
803
823
843
1.52
2.15
2.25
2.52
0.28
0.21
0.44
0.34
c
a T~623 K; b T~773 K; c T~843 K
Fan et al. Effects of strain rate and temperature on flow and microstructure of AA 8090 437
Discussion
FLOW HARDENING
The stress strain curves shown in Figs. 3 and 5 indicate
flow hardening in the early part of deformation, which is
more pronounced towards the lower temperatures and the
higher strain rates. At low temperatures, hardening is
attributed to conventional dislocation related strain hardening,11 but flow hardening during superplastic deformation is attributed to concurrent grain growth. In the present
study, no noticeable grain growth was observed up to the
test temperature of 623 K, but rapid grain growth occurred
at temperatures of 803 K and above. Therefore, flow
hardening at the test temperatures from ambient to 623 K
is suggested to be the result of dislocation dislocation
and dislocation precipitate interactions (Fig. 13a). At
higher test temperatures, concurrent grain growth contributed to flow hardening. However, the evaluation of
the flow hardening contribution of the instantaneous
grain size during superplastic deformation, according
to a method discussed elsewhere,12 suggested that grain
growth could contribute only partly to the observed
extent of flow hardening. Therefore, some flow hardening
in the present material even towards the upper temperature
limit of testing (843 K) may have come from other sources.
One such source appears to be the conventional strain
hardening mechanisms, as suggested by the presence of
significant dislocations (Fig. 13b and c). Although no such
systematic analysis was done for the variation in flow
hardening with strain rate, the greater flow hardening rate
at higher strain rates (Fig. 5) may also be associated with
conventional strain hardening. This is based on observations that the flow behaviour and nature of microstructural
evolution are similar at higher strain rates and lower
temperatures.13,14
438 Fan et al. Effects of strain rate and temperature on flow and microstructure of AA 8090
Conclusions
The study of flow behaviour and microstructural evolution
in AA 8090 Al Li alloy over the strain rate range
161025 161022 s21 and temperature range 298 843 K
led to the following conclusions.
1. Flow hardening occurred in the early part of
deformation, the rate of which increased with an increase
in strain rate and a decrease in temperature. The flow
hardening was suggested to result from the combined effects
of dislocation activity and grain growth.
2. Both strain rate sensitivity index and tensile ductility
were noted first to increase and then to decrease with an
increase in test temperature. However, grain growth
increased continuously with temperature.
Materials Science and Technology
Acknowledgements
The authors would like to thank the consortium of
Manitoba aerospace industries and the Natural Science
and Engineering Research Council of Canada for financial
support. Technical assistance from D. Mardis and J. Van
Dorp is appreciated.
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