Novel Ultra-High Straining Process for Bulk Materials

1
Novel Ultra-High Straining Process for Bulk
MaterialsDevelopment of the Accumulative
Roll-Bonding (ARB) Process

• Authored by Y. Saito, H. Utsunomiya, N. Tsuji, T.
  Sakai
• Presented by Chris Reeve
• September 13, 2004

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Outline

• Introduction
• Model
• Design Application
• Experimental Procedure
• Results
• Conclusion
• Questions

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Introduction

• Why is Accumulative Roll-Bonding important?
• Ultra-fine grain materials exhibit desirable
  properties
• High strength at ambient temperatures
• High-speed superplastic deformation at elevated
  temperatures
• High corrosion resistance
• Commonly accomplished by intense plastic straining

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Introduction

• Processes used such as cyclic extrusion
  compression have two main drawbacks
• Requires large load capabilities, expensive dies
• Low production rate limits economic viability
• Function of paper is to introduce Accumulative
  Roll-Bonding (ARB) as a bulk manufacturing process

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Introduction

• References
• 1. Richert, J. and Richert, M., Aluminum, 1986,
  62, 604
• 2. Valiev, R. Z., Krasilnikov, N. A. and Tsenev,
  N. K., Mater. Sci. Engng, 1991, A137, 35.
• 3. Horita, Z., Smith, D. J., Furukawa, M.,
  Nemoto, M., Valiev, R. Z. and Langdon, T. G., J.
  Mater. Res., 1996, 11, 1880.
• 4. Saito, Y., Utsunomiya, H., Tsuji, N. and
  Sakai, T., Japanese Patent applied for.
• 5. Nicholas, M. G. and Milner, D. R., Br. Weld.
  J., 1961, 8, 375.
• 6. Helmi, A. and Alexander, J.M., J. Iron Steel
  Inst., 1968, 206, 1110.
• 7. Metals Handbook, 9th edn, Vol. 2. American
  Society for Metals, Metals Park, OH, 1979, pp.
  65-66.
• 8. Sakai, T., Saito, Y., Hirano, K. and Kato, K.,
  Trans. ISIJ, 1988, 28, 1028.
• 9. Saito, Y., Tsuji, N., Utsunomiya, H., Sakai,
  T. and Hong, R. G., Scripta mater., 1998, 39,
  1221.
• 10. Tylecote, R. F., The Solid Phase Welding of
  Metals. Edward Arnold, London, 1968.

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Model

• Principle
• Rolling bond surfaces together
• Refines microstructure
• Improves properties.
• Iterative process
• Process design steps
• Surface treatment
• Stacking
• Roll bonding (heating)
• Cutting

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Model

• Important parameters t, tn, n, e, rt
• For reduction of 50 in a pass
• Thickness after n cycles
• t t0 / 2n
• Total reduction after n cycles
• rt 1 t / t0 1 1 / 2n
• Equivalent plastic strain

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Design Application
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Experimental Procedure

• No special equipment needed!
• Three alloys chosen
• Al 1100 (commercially pure)
• Al 5083 (Al-Mg alloy)
• Ti-added interstitial free (IF) steel
• Surfaces degreased, brushed
• Strips were heated
• 50 reduction rolling under dry conditions

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Experimental Procedure
Material Heating Roll Diameter (mm) Roll speed (m/min) Mean Strain Rate (/s)
Al (1100) 473 K x 5 min 225 10 12
Al (5083) 473 K x 5 min 310 43 46
IF Steel 773 K x 5 min 310 43 46
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Results
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Results

• Expected that grain refinement
• Improves mechanical properties related to
  strength
• Decreased elongation in direction of
  roll-bonding
• The number of cycles required to obtain peak
  strength can only be determined experimentally

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Results
Material Cycles TS (MPa) Elongation
Al (1100) 0 (Initial) 84 42
Al (1100) 8 304 8
Al-Mg (5083) 0 (Initial) 319 25
Al-Mg (5083) 7 551 6
IF Steel 0 (Initial) 274 57
IF Steel 5 751 6
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Conclusions

• Practical industrial use for high strength
  structural applications
• Advances rolling technology by application to a
  specific materials processing method
• Industries most impacted construction, marine,
  aerospace, automotive

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Questions???