European Journal of Scientific Research ISSN 1450-216X Vol.26 No.4 (2009), pp.549-557 EuroJournals Publishing, Inc. 2009 http://www.eurojournals.com/ejsr.

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Effects of Degrees of Cold Working and Recrystallisation on the Microstructure and Hardness of Commercial-Purity Aluminum
Zainul Huda Department of Mechanical Engineering, University of Malaya 50603 Kuala Lumpur, Malaysia E-mail: drzainulhuda@hotmail.com Tel: +603 79674593 Abstract The effects of various degrees of cold-working and recrystallization on the microstructure and hardness of commercially-pure aluminum plate have been studied. Experimentation involved cold rolling and recrystallization processes followed by quantitative metallographic practice and the hardness measurements. The plate of commercial-purity aluminum was cold rolled to different degrees of cold-work and then recrystallized by annealing at 180C. The critical deformation for the aluminum has been determined with aid of graphical plots. When increasing the % CW below critical deformation, the grain size was found to increase; however, the grain size was found to decrease with increasing the % C.W above the critical deformation. Keywords: Cold working, critical deformation, recrystallization, microstructure, grain size

1. Introduction
Cold working (CW) and recrystallization annealing are the fundamental phenomena of microstructure evolution in the processing of engineering materials. They are of major scientific interest and of great importance for a wide range of industrial applications. Recent and numerous studies carried out on aluminum alloy sheets have demonstrated that fatigue life of specimens containing a cold worked (CW) open hole can be improved by a factor of 420; this finding is of extreme technological significance in aerospace industries (Burlat, et. al. 2008; Rich and Impellizzeri, 1997; Jongebreur and Dekoning, 1983; She, et. al., 1986; Ozelton, et. al., 1986). Deformation by cold rolling is a process by which the metal is introduced between rollers and then compressed and squeezed at room temperature (below the recrystallization temperature) for reducing its cross sectional area. It is convenient to express the degree of plastic deformation as percent cold work as follows: % cold work = [(A0 - Ad)/ A0] x 100 (1) where A0 = the original area of the cross section, and Ad = the cross-sectional area after deformation. Recrystallization (often called primary recrystallization) is the annealing process involving nucleation and growth of new, strain-free and equi-axed grains in the microstructure of a plastically deformed metal (Vandermeer and Jensen, 2001). The grain size of a recrystallized metallic material depends on the rates of nucleation and subsequent growth of the recrystallized grains (Nah et. al.,

Effects of Degrees of Cold Working and Recrystallisation on the Microstructure and Hardness of Commercial-Purity Aluminum

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2001; Humphreys and Hatherly, 1996). The recrystallization temperature, Tr, may be related to the melting temperature by following relationship: (2) Tr ~ 0.4 Tm where the melting temperature, Tm, is expressed in Kelvin. During recrystallization, the mechanical properties that were changed as a result of cold working are restored to their pre cold-worked values. Cold rolled metal possesses good tensile strength in longitudinal direction; however the strength in the transverse direction may be poor due to elongated grained structure and alignment of inclusions in the rolling direction. This metallurgical problem can be solved by recrystallization heat treatment. The value of critical deformation enables the manufacturers (particularly rolling mills) to keep % deformation (cold working) (CW) well above the critical value to avoid formation of coarse grains in the rolled aluminum products. The critical deformation (% cold-work) is the degree of deformation which is just necessary to initiate recrystallization; thereby resulting in extremely coarse grains in the microstructure of recrystallized metal (Higgins, 1988). Recent research has shown that deformation rate should be raised to a given minimal rate for starting recrystallization depending on the kinds of material (Baki and Halc, 2007). Thus, the energy required for the appearance of new grains can be provided (etintrk, 1993). It has also been reported that if the energy and the grain number required for critical deformation are insufficient, a recrystallized matrix having coarse grains will be produced (Anderson, 1967). In other words, the higher the cold deformation rate, the thinner the grains in the matrix. If the recrystallization temperature is increased, recrystallization can occur at lower cold deformation rates. The recrystallization temperature is reduced when the cold deformation rate is increased (idem and Bennett, 1991, 1998).

2. Experimentation
A plate of commercially-pure aluminum was chosen as the starting material (SM). The experimental work involved use of a rolling mill (Lab mill), metallographic grinding and polishing machines, an optical microscope with computerized imaging system, a Vickers micro-hardness testing machine and a heat treatment furnace. A metallographic sample (1 cm x 1.2 cm) was cut by hacksaw from the plate of given commercial purity aluminum; this sample was designated as sample A. The remaining aluminum-plate was rolled for various degrees of cold working (% deformation); and designated as B1, C-1, D-1, E-1, and F-1 (see Table 1). The rolled sample were, then, recrystallized and designated as B-2, C-2, D-2, E-2, and F-2 (see Table 1). The application of Equ (2) and reference to literature (Rao, 1998) enables us to set 180C as the recrystallization temperature of commercial purity aluminum for the experimentation. Metallographic specimens were prepared for the various samples before and after recrystallization. The photomicrographs were taken for each of the samples before and after rolling and recrystallization with aid of a sophisticated camera-installed optical microscope linked to computer imaging system run by the MSQ software.
Table 1: The designation scheme of cold-rolled samples before and after recrystallization
Cold-Worked Sample Id # A B-1 C-1 D-1 E-1 F-1 Cold-Worked and Recrystallized Sample Id # B-2 C-2 D-2 E-2 F-2

% CW 0 6.23 19.84 29.83 41.23 54

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3. Results and Discussion

3.1. Microstructural Characterization The results of metallographic investigations for the commercially-pure aluminum, before and after cold rolling and recrystallization, are discussed in the following subsections. 3.1.1. The Effects of Cold Rolling on Microstructure The microstructures of commercially-pure aluminum plate before and after cold rolling are shown in Fig 1(a-c). The microstructure of the as-received material (see Fig 1(a)) shows equi-axed grains of aluminum. This microstructural feature enables us to interpret that the as-received material had been recrystallized after cold rolling.
Figure 1(a): Microstructures of aluminum before cold-working (as-received material) (sample A)

Figures 1 (b-c) indicate that with increase in the percentage of deformation, the grains become more elongated in the rolling direction. With increase in % cold working (CW) to 54% reduction (sample F1), the grained structure can be clearly seen to be denser and more elongated in the direction of rolling. The dislocation density increases with increasing cold deformation; new dislocations are created by cold deformation which interacts with those already existing in the material. A considerable redistribution of impurities takes place during rolling; this material behavior results in reduction of segregation effect which was present in the original (as-received) material. At the same time residual coring is eliminated and a more homogeneous product results due to the mechanical mixing action of rolling.

Effects of Degrees of Cold Working and Recrystallisation on the Microstructure and Hardness of Commercial-Purity Aluminum
Figure 1(b): Microstructures of aluminum after cold-working (6.23% C.W) (sample B)

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Figure 1(c): Microstructures of aluminum after cold-working (54% C.W) (sample F-1)

3.1.2. The Effects of Recrystallization on Microstructure and Hardness The microstructures of the cold worked (C.W) (6% CW, 20%CW, 30%CW, 41%CW, and 54%CW) and recrystallized aluminum samples are shown in Fig 2(a-e). The interpretation of optical micrographs in Fig 2 shows that the grain size increases from Figure 2(a) through (b) to Fig 2(c). On the contrary, the grain size decreases from Fig. 2(c) through 2(d) to 2(e). Hence the recrystallization of cold worked for metal may be used to refine the grain structure. The grain refinement through deformation followed by recrystallization is in agreement with the recent literature (Shahani and. Clyne, 2003; Askeland, D.R. and Phule, 2003).

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Figure 2(a): Microstructures of cold-worked (6% C.W) and recrystallized aluminum

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Figure 2(b): Microstructures of cold-worked (20% C.W) and recrystallized aluminum

Figure 2(c): Microstructures of cold-worked (30% C.W) and recrystallized aluminum

Effects of Degrees of Cold Working and Recrystallisation on the Microstructure and Hardness of Commercial-Purity Aluminum
Figure 2(d): Microstructures of cold-worked (41% C.W) and recrystallized aluminum

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Figure 2(e): Microstructures of cold-worked (54% C.W) and recrystallized aluminum

An analysis of the graphical plot in Fig. 3 shows that the grain sizes increase slightly from sample B2 to sample D2 and grain sizes decrease from sample D2 to sample F2. Thus, there is a maxima (point of inflexion) in the curve; it means that after recrystallization, the grain size will increase for lower percentage of deformation and grain size will decrease for deformations greater than 30% C.W. (cold work). For sample D-2, the grain size is the largest; hence the critical deformation for the material investigated is around 30%.

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Figure 3: Graphical plot showing variation of grain size of recrystallized aluminum versus % C.W

GRAPH GRAIN SIZE VERSUS PERCENTAGE OF DEFORMATION AFTER RECRYSTALLIZATION

1.6 GR AIN SIZE (1 0 -4 m 1.5 1.4 1.3 1.2 1.1 0 10 20 30 40 50 60 PERCENTAGE OF DEFORMATION (%) F2 B2 C2 D2 E2

In general, below 30% of deformation (light deformation) will give rise to few nuclei and the resulting grain size will be large. Conversely, above 30% of deformation (heavy deformation) will lead to the deformation of large number regions of high energy within crystals (see Fig 3). This will give rise to production of many nuclei on recrystallization and consequently the grain size will be small. Critical deformation is the degree of deformation (% cold work) which results in the greatest grain size in the recrystallized material (Higgins, 1988). 3.2. Hardness Test Results The analysis of data in Fig 4 indicates that the hardness increases from sample A to sample F1 after cold rolling. This trend in hardness variation is due to strain hardening, which is in agreement with the literature (Anderson, 1967; idem and Bennett, 1991). On application of stress greater than the yield strength (during the cold rolling), number of dislocations increased tremendously. Before deformation, the dislocation density is about 106 cm of dislocation line per cubic cm. of metal. After deformation or strain hardening, the dislocation density might have increased to about 1012 cm of dislocation lines per cm of the metal (Hertzberg, 1996). The graphical plot in Fig. 4 enables us to establish a strong dependence of grain size on hardness. The material behavior observed in Fig 4 clearly indicates that material with fine-grain-size is harder and stronger as compared to sample of the same material with coarse-grain-size. This material behavior is in agreement with the Petch-Hall relationship (John, 1990). The data-analysis for Fig 4 also shows that for deformation below 30% C.W (samples B2 and C2), the hardness values are lower whereas for deformations above 30% C.W (samples E2 and F2), the hardness are higher. The critical deformation (around 30% of deformation) (sample D2) refers to the weakest and softest material at which point the hardness value is about 86.26 HV.

Effects of Degrees of Cold Working and Recrystallisation on the Microstructure and Hardness of Commercial-Purity Aluminum
Figure 4: Plots showing effects of cold rolling and recrystallization on hardness
GRAPH HARDNESS VERSUS PERCENTAGE OF DEFORMATION AFTER COLD ROLLING AND RECRYSTALLIZATION 100 95 90 85 80 75 70 0 HARDNESS (HV

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F2 B2 A B1 C2 C1 D1 D2 E2 E1 F1
COLD ROLLING RECRYSTA LLIZATION

20

40

60

PERCENTAGE OF DEFORMATION (%)

4. Conclusions
The grain refinement in the investigated aluminum has been successfully achieved through cold rolling followed by recrystallization. A strong dependence of % deformation on the grain size has been established for the recrystallized commercial-purity aluminum. When increasing the percentage of deformation below critical deformation, the grain sizes increases. However, the grain size decreases on increasing the % deformation above the critical deformation. For the commercially-pure aluminum plate, the critical deformation percentage was computed to be around 30%. For light deformations (less than the critical deformation) in the recrystallized material, the grain size increases and the hardness decreases. For heavy deformations (higher than the critical deformation) in the recrystallized material, the grain size decreases and the hardness increases and the material exhibits strain hardening behavior.

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Zainul Huda Burlat, M., Julien, D., Lvesque, M., Bui-Quoc, T., Bernard, M., 2008. Effect of local cold working on the fatigue life of 7475-T7351 aluminium alloy hole specimens, Eng. Fracture Mechanics. 75(8) 2042-2061 Rich, D.L, Impellizzeri, L.F., American Society for Testing and Materials, 1997. Fatigue analysis of cold-worked and interference fit fastener holes. In: Cyclic stressstrain and plastic deformation aspects of fatigue crack growth. ASTM STP 637. Philadelphia:15375. Jongebreur, A. A., Dekoning, A.U., 1983. Results of a study of residual stresses and fatigue crack growth in lugs with expanded holes. National Aerospace Lab., NLR, Netherlands. Report NLR-MP-83024-U; She, G.F, Chen, Y., Chen, Y., 1986. Cold expanding of holes improves fatigue-life of aluminum alloy components. In: Fatigue prevention and design. Proc. International Conference, Amsterdam, Netherlands. London: Engineering Materials Advisory Services; 99106. Ozelton, M.W, Coyle TG., ASTM, 1986. Fatigue life improvement by cold working fastener holes in 7050 aluminium. In: Fatigue in mechanically fastened composite and metallic joints. ASTM STP 927. Philadelphia: 5371. Vandermeer, R. A. and Jensen, D. J., 2001. Microstructural path and temperature dependence of recrystallization in commercial aluminum Acta Mater., 49(11) 2083-2094 Nah, J.J., Kang, H.G., Huh, M.Y. and Engler, O., 2008. Effect of strain states during cold rolling on the recrystallized grain size in an aluminum alloy; Scripta Mater.,58 (6) 500-503 Humphreys, F.J. and Hatherly, M., 1996. Recrystallization and Related Annealing Phenomena, Pergamon Press, Oxford, Higgins, R.A., 1988. Engineering Metallurgy, Edward Arnold Press, U.K, Baki, M.K. and Halc, . The effects of homogenization and recrystallization heat treatments on low-grade cold deformation properties of a 6063 aluminum alloy, Materials Letters, 2007, 61(4-5): 944-948 etintrk, S., 1993. The effects of phase distribution on low cold deformation and recrystallization properties of alloys (in Turkish), M. Sci. Thesis, Yldz University, Istanbul, Turkey, Anderson, W.A., 1967. Work-hardening, Recovery, Recrystallization and Grain Growth. In: K.R. Van Hom, Editor, Properties Physical Met. Phase Diagrams, Aluminum Vol. V1, ASM, USA idem, M. and Bennett, G.H.J., 1991. The influence of casting practice on the critical strain and subsequent grain growth of commercial purity aluminum, Materials Science & Engineering A: 141, 141245. idem, M. and. Bennett, G.H.J., 1998. Effect of composition on critical (cold working) strain and recrystallized grain size of dilute AlFe alloys, Materials Science & Technology 7, 835845 Rao, P. N, 1998. Manufacturing Technology: Foundry, Forming and Welding. TATA McGrawHill, India, Shahani, R.A. and. Clyne, T.W., 2003. Re-crystallization in fibrous and particulate metal matrix composites, Materials Science and Engineering, 135, 281-285 Askeland, D.R. and Phule, P.P., 2003 The Science and Engineering of Materials; Thomson Books Inc, USA Hertzberg, R.W., 1996. Deformation and Fracture Mechanics of Engineering Materials; John Wiley and Sons Inc, USA John, V.B., 1990. Engineering Materials, Macmillan Education Ltd, U.K

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