Metallurgy Commons^™

Microstructure And Mechanical Properties Of A Friction Stir Processed Ti-6al-4v Alloy, Jianqing Su, Jiye Wang, Rajiv S. Mishra, Ray Xu, John A. Baumann

Materials Science and Engineering Faculty Research & Creative Works

Friction stir processing (FSP) trials were performed on 2mm-thick Ti-6Al-4V sheets using various processing parameters including tool rotational speed (800-1000RPM) and tool traverse speed (1-4IPM). A processing window was established with the W-1% La₂O₃ tool to produce defect-free friction stir processed (FSP'd) materials. The stir zone (SZ) material of the FSP'd samples showed a fully Β transformed microstructure characterized by typical basket-weave lamellar α/Β structure. The prior Β grains in the SZs contained multiple α variants, and the average sizes ranged from 12μm to 38μm influenced by the processing parameters. Based on metallurgical evaluation, the microstructural evolution …

Superplasticity And Microstructural Stability In A Mg Alloy Processed By Hot Rolling And Friction Stir Processing, V. Jain, R. S. Mishra, R. Verma, E. Essadiqi

Materials Science and Engineering Faculty Research & Creative Works

The superplastic behavior of a Mg-1.2 Zn-1.7 Y-0.53 Al-0.27 Mn alloy sheet processed by hot rolling and friction stir processing (FSP) was investigated. The kinetics of superplastic deformation were compared with Mg-3 Al-1 Zn and other Mg-Zn-Y alloys processed by different methods. The FSP Mg-1.2 Zn-1.7 Y-0.53 Al-0.27 Mn alloy exhibits slower kinetics of deformation compared with other alloys. The microstructural stability of the FSP Mg-1.2 Zn-1.7 Y-0.53 Al-0.27 Mn alloy is better than the Mg-3 Al-1 Zn alloy because of the presence of different types of precipitates. © 2012 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved.

Stress Corrosion Cracking Susceptibility Of Ultrafine Grained Al-Mg-Sc Alloy, G. R. Argade, N. Kumar, R. S. Mishra

Materials Science and Engineering Faculty Research & Creative Works

General corrosion and stress corrosion cracking (SCC) behavior of coarse grained, fine grained and ultrafine grained (UFG) AA5083 and Al-Mg-Sc-Zr alloy in different thermomechanical conditions were studied in the present work. Friction stir processing (FSP) was carried out to refine the grain size. The average grain size achieved after FSP for AA5083 was 7±3μm, whereas that for Al-4Mg-0.8Sc-0.08Zr was 0.39±0.16μm with 100% UFG microstructure. Linear polarization resistance and cyclic polarization techniques were used to study general corrosion behavior of these alloys in 3.5wt% NaCl solution. The UFG microstructure showed the highest polarization resistance (Rp) of ~93kΩ which increased to ~160kΩ …

High Strain Rate Superplasticity In Friction Stir Processed Ultrafine Grained Mg-Al-Zn Alloys, A. Mohan, W. Yuan, R. S. Mishra

Materials Science and Engineering Faculty Research & Creative Works

Friction stirs processing of a rolled AZ31 alloy, and a high pressure die cast AZ91 alloy produced ultrafine grained materials with average grain size of 0.8μm and 0.5μm, respectively. Tensile testing was done in the temperature range of 210-360°C and strain rate range of 1x10^-4-3x10^-2s^-1. Higher amounts of Β-precipitates in AZ91 thermally stabilized the microstructure up to 330°C. Friction processed ultrafine grain AZ91 exhibited high strain rate super plasticity at all tested temperatures. The best elongation of 1251% was achieved at a strain rate of 1x10^-2s^-1 and temperature of 330°C. The …

Effect Of Friction Stir Processing On The Tensile And Fatigue Behavior Of A Cast A206 Alloy, R. Kapoor, K. Kandasamy, R. S. Mishra, J. A. Baumann, G. Grant

Materials Science and Engineering Faculty Research & Creative Works

The microstructure of cast Al alloy A206 was modified using friction stir processing (FSP) to eliminate porosity, break down intermetallic particles and refine the grains. The inference from differential scanning calorimetry is that the nugget region of the as-FSP material contained primarily GP zones. Uniaxial tensile tests and bending fatigue tests were carried out at room temperature on A206 alloy in the cast and T4 conditions and after FSP with different heat treatments - as-FSP, FSP and aging, and FSP with solutionizing and aging. These produced varied microstructures with combinations of pores, grain sizes, precipitate types and particle sizes. The …

Effect Of Inhomogeneous Deformation On Anisotropy Of Az31 Magnesium Sheet, Jidong Kang, David S. Wilkinson, Raja K. Mishra, Wei Yuan, Rajiv S. Mishra

Materials Science and Engineering Faculty Research & Creative Works

Inhomogeneous plastic deformation in AZ31 magnesium sheet has been studied during uniaxial tensile testing using digital image correlation and electron backscatter diffraction techniques. Large strain gradients develop on the sheet surface parallel and perpendicular to the loading direction while very little deformation occurs in the thickness direction. This lack of thinning leads to an abrupt fracture following the development of a premature but extensive diffuse neck but without any localized neck. The strain distribution on the sheet surface evolves nonlinearly with strain, impacting the measured plastic strain ratio, r-value. The results show that r-value should be measured at "points" rather …

Microstructure And Mechanical Properties Of Friction Stir Welded Oxide Dispersion Strengthened Alloy, Jiye Wang, Wei Yuan, Rajiv S. Mishra, Indrajit Charit

Materials Science and Engineering Faculty Research & Creative Works

Effect of friction stir welding (FSW) on microstructure and mechanical properties of oxide dispersion strengthened alloy MA956 was investigated. Fine grained microstructure was developed in the processed region with slight particle coarsening. Tensile behavior of the processed material was compared with that of the as-received material at room temperature. Results indicated that significant grain refinement during FSW compensated for the reduced particle strengthening contribution and enhanced tensile strength by 145 MPa without loss in ductility. Further analysis indicated a good agreement between experimentally measured yield strength and the strength calculated by Pythagorean superimposition of strengthening contribution in FSWed material. © …

On The Effect Of Silicon And Phosphorus During The Precipitation Of Κ-Carbide In Fe-Mn-Al-C Alloys, Laura Bartlett

Doctoral Dissertations

"Implementation of lightweight high manganese and aluminum steels for use in high energy absorbing applications requires a detailed knowledge of how alloying additions and impurities affect age hardening and high strain rate fracture properties. Dynamic fracture toughness is an important design criterion but has not been reported previously in these alloys. In addition, previous studies have shown that silicon and phosphorus increased the strength and aged hardness; however, the mechanism was unknown. This research mainly focuses on the effect of silicon and phosphorus on the precipitation of Κ-carbide and alloy partitioning during aging. Short range ordering, SRO, of Fe-Al-C into …

Grain Size And Texture Effects On Deformation Behavior Of Az31 Magnesium Alloy, W. Yuan, R. S. Mishra

Materials Science and Engineering Faculty Research & Creative Works

Cold rolled AZ31 magnesium alloy sheet was subjected to friction stir processing to generate four average grain sizes ranging from 0.8 to 9.6 μm. the processed material exhibited a strong basal fiber texture with the c-axis tilted about 35-55° towards the processing direction. the grain size and texture dependence of mechanical behavior were evaluated by using tensile testing along two orthogonal directions. Remarkably high ductility of ~65% was achieved in relatively coarse-grained material that fractured without developing necking when tested in the processing direction. the ductility decreased significantly to ~10% for ultrafine grained material as the tensile yield strength increased …

A Comparative Study On The Corrosion Resistance Of Cerium-Based Conversion Coatings On Az91d And Az31b Magnesium Alloys, C. E. Castano, Surender Maddela, Matthew J. O'Keefe, Y. M. Wang

Materials Science and Engineering Faculty Research & Creative Works

In the present work a comparative study has been carried out on the surface morphology, electrochemical properties and corrosion performance of cerium-Based conversion coatings (CeCCs) on AZ91D and AZ31B magnesium alloys. the as-deposited coatings consisted of a two-layer structure: A continuous Mg/Al oxide transition layer of ∼ 50 nm thick and a CeCC layer of ∼ 400 nm thick. Potentiodynamic polarization and impedance spectroscopy results using a 0.6 wt.% NaCl and 0.6 wt.% (NH₄)₂SO₄ electrolyte showed that cerium-Based conversion coatings enhanced the corrosion resistance of AZ91D and AZ31B magnesium alloys compared to polished uncoated samples. …

Stress Corrosion Cracking Susceptibility Of Ultrafine Grained Az31, G. R. Argade, W. Yuan, K. Kandasamy, R. S. Mishra

Materials Science and Engineering Faculty Research & Creative Works

In this study, stress corrosion cracking (SCC) behavior of AZ31 magnesium alloy was carried out using slow strain rate testing (SSRT) technique in 3.5 wt.% NaCl solution. the influence of microstructural scale on the stress corrosion behavior was investigated in AZ31 alloy with three different mean grain sizes. Single-pass and two-pass friction stir processing (FSP) was employed to obtain fine grain and ultrafine grain microstructures, respectively. for FSP, SSRT specimens were extracted from the processed region. SSRTs were carried out in air and solution at an initial strain rate of 10 -6/s. a significant decrease in the ultimate tensile strength …

Transition Of Deformation Behavior In An Ultrafine Grained Magnesium Alloy, S. K. Panigrahi, K. Kumar, N. Kumar, W. Yuan, R. S. Mishra, R. Delorme, B. Davis, R. A. Howell, K. Cho

Materials Science and Engineering Faculty Research & Creative Works

The deformation behavior of friction stirs processed magnesium alloy with average grain size ranging from 25 μm to 240 nm was studied. an evaluation of critical grain size for transition of deformation mode from twinning to slip was carried out by employing tensile and compressive tests. the role of critical grain size in transition of deformation behavior from strain hardening to softening was established. Inhomogeneous yielding was observed during tensile test of ultrafine-grained magnesium alloy below the critical grain size. © 2012 Elsevier B.V.

Process Optimization For Friction-Stir-Welded Martensitic Steel, M. Ghosh, K. Kumar, R. S. Mishra

Materials Science and Engineering Faculty Research & Creative Works

Advanced high-strength M190 steel sheets were joined by friction-stir welding under different tool rotational and traversing speeds. the optical microstructure of the joints exhibited complete martensite and partial martensite at the weld nugget depending on the cooling rate during welding. the first heat-affected zone outside of the weld nugget revealed ferrite-pearlite phase aggregate, and the second heat-affected zone showed a tempered martensitic structure. the interplay of process variables in terms of peak temperature and cooling rate was studied to observe their effect on joint efficiency under shear testing. the peak hardness at weld nugget was close to the parent alloy …

Material Flow And Microstructural Evolution During Friction Stir Spot Welding Of Az31 Magnesium Alloy, W. Yuan, Rajiv S. Mishra, B. Carlson, R. Verma, R. K. Mishra

Materials Science and Engineering Faculty Research & Creative Works

Material flow and local texture evolution during friction stir spot welding (FSSW) of AZ31 magnesium alloy was characterized by varying tool rotation rates. Texture at various locations of the welded region was measured using electron backscatter diffraction (EBSD). Material flow is significantly influenced by tool rotation rate with a conical step spiral pin tool, and FSSW introduces a unique basal fiber texture in the welded region. Results indicate that local texture evolution is dominated by shear deformation through material flow. the tool shoulder applies both shear and compressive deformation to the upper region material; however, the rotating pin introduces only …

Hot Deformation Behavior Of Friction-Stir Processed Strip-Cast 5083 Aluminum Alloys With Different Mn Contents, M. A. García-Bernal, Rajiv S. Mishra, R. Verma, D. Hernández-Silva

Materials Science and Engineering Faculty Research & Creative Works

Fine grained 5083 aluminum alloy is the most common Al-Mg alloy for superplastic forming (SPF) of lightweight sheet metal parts in the automotive and aerospace industries. the fine-grained sheet is industrially produced by massive cold rolling of conventionally rolled sheet stock at high cost. Friction stir processing (FSP) as a thermomechanical process is very effective in refining the microstructure of as-cast alloys such as that produced by continuous strip casting (CC). in this work, the effect of friction stirs processing on the superplastic properties of three CC 5083 aluminum alloys, with different Mn content, has been investigated. the three alloys …

Plastic Strain Accommodation And Acoustic Emission During Melting Of Embedded Indium Particles In Aluminum, Michael M. Kuba

Masters Theses

"Melting of micron-sized (0.2 to 3 µm diameter) indium particles embedded in an aluminum matrix was discovered to produce acoustic emission. Melting of embedded immiscible particles produces a pure dilation during the phase transformation and has no long-range diffusion field to control the speed of transformation. It was found that acoustic emission can no longer be considered as a criterion of displacive transformations and that melting of micron-sized embedded particles is strain energy controlled. Acoustic emission was confirmed to result from the rapid relaxation of aluminum around indium particles embedded on grain boundaries. Prismatic punching of dislocation loops is proposed …

Directional Anisotropy In The Mechanical Behavior Of Friction Stir Processed And Aged Az91 Alloy, Vipin Jain, Wei Yuan, R. S. Mishra, Gouthama, Anil K. Gupta

Materials Science and Engineering Faculty Research & Creative Works

Friction stir processing (FSP) is an emerging grain refinement technique for magnesium alloys. in this study, a cast AZ91 alloy was processed by a single-pass FSP to achieve an average grain size of ∼6 μm in the nugget zone. the FSP is found to introduce texture in the alloy due to preferred alignment of basal poles in the processing direction. the mechanical behavior is significantly influenced by texture. after FSP, the alloy was aged at different temperatures and times for continuous and discontinuous precipitation of β-Mg17Al12. a high anisotropy in yield stress is observed in the processing and transverse direction …

Development Of Third Generation Advanced High Strength Steels, Meghan C. Mcgrath

Doctoral Dissertations

"Lightweight duplex steels with combinations of either bainite, acicular ferrite, and austenite or martensite and austenite were investigated as third generation advanced high strength steels targeted for automotive applications. Large additions of manganese (>13 wt%) and carbon (

Duplex steels with different volume fractions of primary δ -ferrite were used to study the crystallography of austenite formed during the peritectic reaction. Solute profiles across the peritectic interface showed aluminum segregated near the interface which promoted bainitic ferrite formation. Thermal treatments were used to manipulate the concentration and type of oxides and the ferrite plate density was found to correlate …

Friction Stir Welding Of High Temperature Alloys, Jiye Wang

Doctoral Dissertations

"Friction stir welding (FSW) of Ti-6Al-4V alloy, nickel-based and iron-based oxide dispersion strengthened (ODS) alloys (MA754 and MA956) has been studied. The main aspects covered include tool evaluation, microstructural evolution, mechanical properties, and correlation between processing, microstructure and mechanical properties. Tool performance study was carried out for Ti-6Al-4V alloy with refractory tools made of W-1.1%La₂O₃ and two different grades of WC-Co based materials. The results showed that tool degradation can be attributed to mechanical and chemical interaction with processed material. The nature of tool-workpiece interaction was tool material dependent and influenced the resultant microstructure and weld quality in the stirred …

Influence Of Microstructural Length Scale On Deformation Behavior Of Magnesium Alloys, Wei Yuan

Doctoral Dissertations

"Friction stir processing (FSP) is emerging as an effective tool for microstructural modification. Mg-Al-Zn alloys with different aluminum contents were subjected to FSP to achieve fine grained and ultrafine grained (UFG) structure. The objective of this work was to study the influence of microstructural length scale on the governing deformation and strengthening mechanisms of FSP magnesium alloys.

FSP introduced strong basal fiber texture and processing parameter dependent grain/precipitate size and distribution. Grain refinement promoted non-basal dislocation activation at room temperature. The strength of the alloy increased as a consequence of grain refinement following classic Hall-Petch relationship to different extents due …

Influence Of Grain Size And Texture On Hall-Petch Relationship For A Magnesium Alloy, W. Yuan, S. K. Panigrahi, J. Q. Su, R. S. Mishra

Materials Science and Engineering Faculty Research & Creative Works

Friction stir processing was applied to a magnesium alloy to generate various grain sizes with the same intense basal texture. Subsequent tensile deformation along two orthogonal directions by easy activation or inhibition of basal slip follows the Hall-Petch relationship between yield stress and grain size in both directions. the Hall-Petch parameters are texture dependent. Easy activation of basal slip introduces lower values, while inhibition of basal slip leads to higher values. the Hall-Petch parameters are interpreted by texture and microstructural factors. © 2011 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved.

Grain Boundary Behavior In An Ultrafine-Grained Aluminum Alloy, P. S. De, R. S. Mishra

Materials Science and Engineering Faculty Research & Creative Works

The low-angle grain boundary (LAGB) stability in an ultrafine-grained (UFG) Al alloy during monotonic loading was investigated by orientation imaging microscopy (OIM). the experiments show that boundaries with misorientation below ∼2.5 deg are stable, while boundaries with misorientation between 2.5 and 15 deg are unstable. Similar results were observed during cyclic loading of UFG Al alloy. This behavior was rationalized using the nonequilibrium thermodynamics concept. on the other hand, it is postulated that the grain boundary behavior in microcrystalline alloy is different because of the larger dislocation mean free path. © 2011 the Minerals, Metals & Materials Society and ASM …

Probabilistic Fatigue Life Prediction Model For Alloys With Defects: Applied To A206, R. Kapoor, Vittal S. Rao, R. S. Mishra, J. A. Baumann, G. Grant

Electrical and Computer Engineering Faculty Research & Creative Works

A model for the prediction of fatigue life based on the statistical distribution of pores, intermetallic particles and grains is presented here. This has been applied to a cast Al alloy A206 before and after friction stir processing (FSP). the model computes the probability of initiating a small crack based on the probability of finding combinations of defects and grains on the surface. Crack initiation and the propagation life of small cracks due to these defect and grain combinations are computed and summed to obtain the total fatigue life. the defect and grain combinations are ranked according to total fatigue …

Calcium Wire Ladle Treatment To Improve Cleanliness Of Centrifugal Cast Steel, Edith Yolanda Martinez Silva

Masters Theses

"Centrifugal casting provides the opportunity of combining large centrifugal forces and directional solidification to reduce non-metallic inclusions in the cast steel product. Calcium treatment in the ladle has the potential of reducing and modifying non-metallic inclusions to achieve better machinability and mechanical properties. The objective of this research is to analyze the combined effects of calcium wire ladle treatment and centrifugal casting on the number, size, composition and morphology of non-metallic inclusions in centrifugally cast steel products.

All experiments were completed at an industrial foundry. The experiments involved feeding calcium wire into the ladle after argon oxygen decarburization (AOD) and …

Crack Formation In Investment Casting Ceramic Shells, W. A. Everhart

Masters Theses

"This thesis is a collection of papers that discuss shell cracking in investment casting during pattern removal. The application of rigid polymeric foam for large investment casting patterns with complex geometries can improve the dimensional tolerances and the surface quality of the casting. However, these pattern materials have a tendency to promote crack formation in investment casting shells during pattern removal by firing.

The first two papers discuss the factors affecting shell cracking and methods to prevent it. Experimental methods were combined with finite element modeling to predict stress in the shell. A 3D nonlinear finite element model was developed …

A Study On The Combined Effect Of Forging And Aging In Mg-Y-Re Alloy, S. K. Panigrahi, W. Yuan, R. S. Mishra, R. Delorme, B. Davis, R. A. Howell, K. Cho

Materials Science and Engineering Faculty Research & Creative Works

The combined effect of forging and aging on microstructural evolution and mechanical properties of a Mg-Y-RE alloy was studied in the present work by employing hardness measurements, tensile tests, optical microscopy (OM), scanning electron microscopy (SEM) and electron back scattered diffraction (EBSD) analysis. the -F temper treated bulk Mg-Y-RE alloy samples were subjected to forging for microstructural refinement and subsequent aging to maximize the strength-ductility combination. the forged samples combined with peak aging treatment (60 h at 180 °C) exhibited an excellent combination of high strength (388 MPa) and high ductility (23%). the combined effect of grain refinement, work hardening, …

A Stress-Strain Model For A Two-Phase Ultrafine-Grained Aluminum Alloy, P. S. De, J. Q. Su, R. S. Mishra

Materials Science and Engineering Faculty Research & Creative Works

Two-phase ultrafine-grained (UFG) aluminum alloys with different precipitate and low-angle boundary distributions were examined for their monotonic stress-strain behavior. Precipitates in combination with low-angle grain boundaries were found to determine the deformation micro mechanism. It is proposed that thermally activated vacancy movement plays a central role in this regard. the experimental stress-strain curves matched well with the trend predicted by a modified Blum-Zheng model based on vacancy-assisted dislocation annihilation mechanism. © 2010 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved.

Friction Stir Lap Welded Advanced High Strength Steels: Microstructure And Mechanical Properties, M. Ghosh, K. Kumar, R. S. Mishra

Materials Science and Engineering Faculty Research & Creative Works

Friction stir welding was carried out under different heat input and cooling rates to produce lap joints between high strength martensitic steel sheets. the microstructure of the welds was characterized, and microhardness was evaluated. Joint efficiency was determined by lap shear test. Variation in processing conditions governed total heat input, peak temperature and cooling rate during friction stir welding. Weld nugget microstructure depended principally on cooling rate. the slowest cooling rate promoted ferrite-pearlite and the fastest cooling rate resulted in martensite formation in the weld nugget. the weakest region of all the joints was the heat affected zone, which consists …

Alloy Dissolution In Argon Stirred Steel, Darryl S. Webber

Doctoral Dissertations

"Alloying is required for the production of all steel products from small castings to large beams. Addition of large quantities of bulk alloys can result in alloy segregation and inconsistent alloy recovery. The objective of this research was to better understand alloy dissolution in liquid steel especially as it relates to Missouri S&Ts' patented continuous steelmaking process. A 45-kilogram capacity ladle with a single porous plug was used to evaluate the effect of four experimental factors on alloy dissolution: alloy species, alloy size or form, argon flow rate, and furnace tap temperature. Four alloys were tested experimentally including Class I …

Effect Of Process Parameters On Abnormal Grain Growth During Friction Stir Processing Of A Cast Al Alloy, S. Jana, Rajiv S. Mishra, J. A. Baumann, G. Grant

Materials Science and Engineering Faculty Research & Creative Works

The effects of process parameters and friction stir processing (FSP) run configurations on the stability of nugget microstructure at elevated temperatures were evaluated. Cast plates of an Al-7Si-0.6Mg alloy were friction stir processed using a combination of tool rotation rates and tool traverse speeds. All single pass runs showed some extent of abnormal grain growth (AGG), whereas multi-pass runs were more resistant to AGG. Additionally, higher tool rotation rate was found to be beneficial for controlling AGG. These effects were analyzed by comparing the result of this work with other published results and AGG models. © 2010 Elsevier B.V.