Duże odkształcenie plastyczne SPD to technika stosowana w produkcji materiałów o ultradrobnej strukturze (UFG), oparta o intensywne rozdrobnienie ziarna. Dla procesu tego bezwzględnie najważniejsza jest sprawność. Najbardziej znanymi technologiami, które są aktualnie najintensywniej rozwijane są: ECAP, C2S2, CONFORM, HPT, CCDC, ARB oraz CGP. W opracowaniu dokonano analizy technologii ECAP, gdzie istotna poprawa sprawności procesu osiągana jest przez zmianę technologii narzędzia, a przez to zmianę ścieżki deformacji, co znacznie przybliża wizję wdrożenia tej technologii do przemysłu. Wpływ zmiany geometrii wkładki narzędzi ECAP na osiągnięcie wysokiego stopnia odkształcenia, z czym wiąże się wzrost sprawności procesu (tzn. osiągnięcie wymaganej średniej wielkości ziarna przy mniejszej ilości przejść przez narzędzie formujące) przedstawiono na przykładzie stopu AlMn1Cu wyprodukowane przez firmę AL Invest Bridlicna a.s. Dokonano zarówno matematycznej symulacji, jak i fizycznego przeciśnięcia próbek przez narzędzie ECAP. Badanie zostało skoncentrowane na podwyższeniu twardości i średniej wielkości ziarna w klasycznej geometrii kanałów ECAP w porównaniu z narzędziem ECAP o zmodyfikowanej geometrii, gdzie kanał poziomy został odchylony o 20° względem osi „x”, oraz w porównaniu z geometrią, gdzie w kanale poziomym utworzona została linia śrubowa (elektroerozyjnie). Dodatkowo, dla poszczególnych rodzajów geometrii ECAP wykonana została analiza metalograficzna struktury z wykorzystaniem transmisyjnej mikroskopii elektronowej (TEM) oraz przez pozyskanie obrazów dyfrakcyjnych w wybranych obszarach próbki (SAED). Sprawność nowego projektu została jednoznacznie potwierdzona.
EN
Severe plastic deformation is basic process used in technologies for production of ultra-fine grained materials (UFG), using the principle of high disintegration of grain. Efficiency of the given process is therefore of utmost importance. The best known technologies that are currently being intensively developed are the following ones: ECAP, C2S2, CONFORM, HPT, CCDC, ARB and CGP. The paper analyses the ECAP technology, where substantial enhancement of the process efficiency is achieved by change of tool geometry and therefore by change of deformation route, which significantly approaches implementation of this technology into industrial practice. Influence of change of geometry of the ECAP tool insert on achievement of high degree of deformation and thus on the increased efficiency of the process (i.e. achievement of the required mean grain size at significantly lower number of passes through the forming tool) has been demonstrated on the alloy AlMn1Cu manufactured by the company AL Invest Bridlicna a.s. Both mathematical simulation and practical extrusion of samples through the ECAP tool have been performed. Research was focused on the resulting magnitude of hardness and mean grain size in classical geometry of ECAP channels in comparison with modified geometry of the ECAP tool, where horizontal channel was deflected in respect to the axis “x“ by 20°, and in comparison with geometry, when helical line was created (by sparking) into part of horizontal channel. Moreover, metallographic analysis of structure realised on TEM and SAED was applied to individual types of ECAP channel geometry. Efficiency of new design has been confirmed unequivocally.
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Purpose: Paper presents results of progress ECAP processing method for UFG structure reached (gained). The properties and microstructure are influenced by technological factors during application ECAP method. Design/methodology/approach: Summary of methods studied on Department of technology at Machining faculty of VŠB-TU Ostrava through of co-operation with Institute of Engineering Materials and Biomaterials, Silesian University of Technology is presented. Findings: Achievement of ultra-fine grained structure in initial material leads to substantial increase of plasticity and makes it possible to form materials in conditions of „superplastic state“. Achievement of the required structure depends namely of the tool geometry, number of passes through the matrix, obtained deformation magnitude and strain rate, process temperature and lubrication conditions. High deformation at comparatively low homologous temperatures is an efficient method of production of ultra-fine grained solid materials. The new technologies, which use severe plastic deformation, comprise namely these techniques: High Pressure Torsion, Equal Channel Angular Pressing = ECAP, Cyclic Channel Die Compression = CCDC, Cyclic Extrusion Compression = CEC, Continuous Extrusion Forming = CONFORM, Accumulative Roll Bonding, Constrained Groove Pressing. Research limitations/implications: Achieved hardness and microstructure characteristics will be determined by new research. Practical implications: The results may be utilized for a relation between structure and properties of the investigated materials in future process of manufacturing. Originality/value: These results contribute to complex evaluation of properties new metals after application unconventional forming methods. The results of this paper are determined for research workers deal by the process severe plastic deformation.
Several types of SPD technologies serving for production of UFG metals was developed already at the beginning of the nineties. One of them is new type of equipment DRECE (Dual Rolling Equal Channel Extrusion), designated for obtaining UFG structure in strip of sheet. Experiments with use of material Cu 99.5% were made on the DRECE machines in order to achieve grain refinement in the strip of sheet with dimensions 58x2x1000 mm. For orientation information, whether grain was refined preliminary metallographic analysis was made on optical microscope NEOPHOT 2. Structure was analysed on the surface in longitudinal direction in respect to direction of rolling, and also in cross section and longitudinal section. After DRECE machinery the annealing on part of extruded sheets was applied. Two procedure 400 and 450oC/15min/air were selected.
PL
Obecnie rozwinięte kilka technologii SPD przy wytwarzaniu metali UFG. Jedną z nich jest urządzenie DRECE (Dual Rolling Equal Channel Extrusion), opracowane w celu uzyskania struktury UFG w taśmach stalowych. Badania przy zastosowaniu miedzi 99,5% przeprowadzono na maszynie DRECE. Umożliwiło to rozdrobnienie ziarna w taśmach stalowych o wymiarach 58x2x1000 mm. W celu uzyskania informacji czy ziarno zostało rozdrobnione przeprowadzono badania metalograficzne na mikroskopie optycznym NEOPHOT 2. Przeanalizowano strukturę na powierzchni w kierunku wzdłużnym (w kierunku walcowania) a także na przekroju poprzecznym i wzdłużnym. Następnie blachy poddano 15-minutowemu wyżarzaniu w temperaturze 400 i 450 oC.
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Purpose: Paper presents results of investigations with two layers explosively formed sandwich composite consisting of different composition joint which requires very often knowledge of structure and mechanical properties. These properties are connected with microstructure that is influenced by technological factors under cladding. Design/methodology/approach: The sample bars were prepared from explosively formed sandwich composite near the join area. The methods of the light microscopy and the hardness and tensile test for evaluation of quality of joined sandwich metals were used. Investigations by a new fatigue method in the case sandwich composite steel CrNi(18/10) + Ti were completed. Findings: Measurement of micro-hardness in the zone of the joint a deformation of materials shows an increase value of that. Detailed metallographic observation detected in proximity of the joints an occurrence of structural non-homogeneities. Steel and titanium interface surfaces are corrugated. New fatigue method in the case sandwich composite steel CrNi(18/10) + Ti were verified. Research limitations/implications: Knowledge of microstructure characteristics will be extended by the method of SEM, including micro-analysis of individual structural components and surface analysis. Influence of experiment conditions on results of fatigue test must be more elaborated in future. Practical implications: The results may be utilized for a relation between structure and properties of the investigated materials in process of manufacturing. Originality/value: These results contribute to complex evaluation of properties explosively formed sandwich composite namely for explanation of structure developed new sandwich composites. The results of this paper are determined for research workers deal by development new exploitations of new sandwich composites.
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Purpose: Paper presents results of investigations mechanical properties and microstructure samples selected nonferrous metals after ECAP. These properties and microstructure are influenced by technological factors during application ECAP method. Design/methodology/approach: The sample bars were plastically deformed during the ECAP process. The methods of the light microscopy and the hardness test for evaluation of mechanical properties and microstructure were used. Findings: Measurement of micro-hardness shows an increase value after application higher number of passes in agreement with ultra high fine grain occurrence. The method determines the dependencies of force on the route during the ECAP process. Research limitations/implications: Achieved hardness and microstructure characteristics will be determined by new research. Practical implications: The results may be utilized for a relation between structure and properties of the investigated materials in future process of manufacturing. Originality/value: These results contribute to complex evaluation of properties new nonferrous metals after application ECAP method. The results of this paper are determined for research workers deal by the process severe plastic deformation.
Magnesium is a lightest of all structural metals. Although magnesium does not occur in nature in the metallic form, magnesium compounds occur worldwide. Magnesium has been used for wide variety applications, including pyrotechnics and metallurgical, chemical, electrochemical, and structural applications. Magnesium and magnesium alloys are primarily used in aeronautical and automobile industry in wide variety of structural characteristics because of their high strength-to-weight ratios (tensile strength/density), comparable !o those of other structural metals. Magnesium has relatively good electrical conductivity and thermal conductivity. It also has a very high damping capacity that means the ability to absorb elastic vibrations [1 -4]. For practical design are usually used two categories of maginesium alloys: First category (I.) represents magnesium alloys with content of 2-10 % of Al, pertinently with minor content of Zn and Mn. These alloys are produced with low (relatively low) costs and their mechanical quality rapidly fails down at higher temperatures. Second category (II.) represents magnesium alloys with wide variety of chemical elements (for ex. Zn. Th, Ag and Si) instead of Al, but always with effectively low content of Zr which means close-grained structure and higher mechanical quality. These alloys have better characteristics at higher temperatures but more expensive elements together with special production technology means higher production costs.
Synthetic polymers are represented by an extensive range of materials, which play nowadays a completely irreplaceable role in numerous technical applications. Unusually rapid and universal expansion of production and processing of polymers has several principal causes. On one hand the polymers can replace conventional materials (metals, ceramics, wood, leather, wool, natural caoutchouc, etc.), on the other hand their properties enable quite new applications and novel solutions of material problems. Many polymers are made from comparatively cheap and easily available raw materials and they can therefore substitute scarce and expensive materials. Another advantage of polymers consists in the fact that they have low density, as well as often very good electric insulation properties and comparatively high resistance to corrosion. The polymers can be moreover very easily processed by forming. Nevertheless, the polymers have obviously not only advantages, but some drawbacks as well. They comprise usability of polymers only in limited temperature interval, difficult repairs of products made of them and rather complicated regeneration of wastes [1]. Evaluation of polymeric materials from the viewpoint of their suitability for individual industrial applications requires a broad range of testing methods. The most important are tests aimed at mechanical properties [2]. Tensile tests of plastic materials are described in detail in the standards [3]. Another mechanical test used for testing of plastic materials is standardised hardness test according to Brinell. In some polymers we observe differences between hardness values in dependence on load and time. This applies mainly to thermoplastics, The hardness values at lower loads cannot be compared with the values at higher loads. The authors have chosen for the purposes of the present paper commercial samples used in automotive industry. Test pieces were made namely from Terluran, Crastin and Lucryl. Table 1 gives selected mechanical properties of tested plastic materials. Figure 1 shows the hardness values of selected plastics at various durations of indentor. It is obvious that duration of load has a significant impact on the measured hardness values according to Brinell HB.
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Purpose of this paper is to extend a complex evaluation of magnesium alloys which requires very often knowledge of structure and mechanical properties. These properties are connected with microstructure that is influenced by metallurgical and technological factors and conditions of exploitation. Presented knowledge expresses very important information for design and exploitation of these alloys. Design/methodology/approach: The methods of the light microscopy for metallographic and analyses of alloys were used. Findings: Objective of this work consisted in determination of structure and mechanical properties progressive magnesium alloys. Research limitations/implications: Knowledge of alloys structure characteristics will be determined new research direction of scope. Practical implications: The results may be utilized for a relation between structure and properties of the investigated material in process of manufacturing. Originality/value: These results contribute to complex evaluation of properties magnesium alloys namely for explanation of structure developed new magnesium alloys. The results of this paper are determined for research workers deal by development new exploitations of magnesium alloys.
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Purpose: In the following paper there have been presented the optimisation of heat treatment condition and structure of the MCMgAl12Zn1, MCMgAl9Zn1, MCMgAl6Zn1, MCMgAl3Zn1 magnesium cast alloy as-cast state and after a heat treatment. Design/methodology/approach: Working out of a neural network model for simulation of influence of temperature, solution heat treatment and ageing time and aluminium content on hardness of the analyzed magnesium cast alloys. Findings: The different heat treatment kinds employed contributed to the improvement of mechanical properties of the alloy with the slight reduction of its plastic properties. Research limitations/implications: According to the alloys characteristic, the applied cooling rate and alloy additions seems to be a good compromise for mechanical properties and microstructures, nevertheless further tests should be carried out in order to examine different cooling rates and parameters of solution treatment process and aging process. Practical implications: For comparison of the achieved results on the basis of the performed investigations a computer neural network model was used for analysis of the aluminium content and heat treatment parameters influence on the properties of the worked out cast magnesium alloys. Originality/value: The advantage of the neural networks is their capability to learn and adapt to the changing condition, as well as their capability to generalise the acquired knowledge.
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Purpose: In the following paper there have been the properties of the MCMgAl12Zn1, MCMgAl9Zn1, MCMgAl6Zn1, MCMgAl3Zn1magnesium cast alloy as-cast state and after a heat treatment presented. Design/methodology/approach: A casting cycle of alloys has been carried out in an induction crucible furnace using a protective salt bath Flux 12 equipped with two ceramic filters at the melting temperature of 750 ± 10*C, suitable for the manufactured material. The following results concern abrasive wear, mechanical properties, light and scanning microscopy. Findings: The different heat treatment kinds employed contributed to the improvement of mechanical properties of the alloy with the slight reduction of its plastic properties. Research limitations/implications: According to the alloys characteristic, the applied cooling rate and alloy additions seems to be a good compromise for mechanical properties and microstructures, nevertheless further tests should be carried out in order to examine different cooling rates and parameters of solution treatment process and aging process. Practical implications: The concrete examples of the employment of castings from magnesium alloys in the automotive industry are elements of the pedals, dashboards, elements of seats, steering wheels, wheel bands, oil sumps, elements and housings of the gearbox, framing of doors and sunroofs, and others, etc. Originality/value: Contemporary materials should possess high mechanical properties, physical and chemical, as well as technological ones, to ensure long and reliable use. The above mentioned requirements and expectations regarding the contemporary materials are met by the non-ferrous metals alloys used nowadays, including the magnesium alloys.
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Purpose: Main aim of this paper is to describe the structure of the MCMgAl12Zn1 magnesium cast alloy as-cast state and after a heat treatment. Design/methodology/approach: The following results concern metallographic examinations, the X-ray qualitative and quantitative microanalysis, X-ray diffraction method. Findings: The different heat treatment kinds employed contributed to the improvement of mechanical properties of the alloy with the slight reduction of its plastic properties. Research limitations/implications: According to the alloys characteristic, the applied cooling rate and alloy additions seems to be a good compromise for microstructures, nevertheless further tests should be carried out in order to examine different cooling rates and parameters of solution treatment process and aging process. Practical implications: The concrete examples of the employment of castings from magnesium alloys in the automotive industry are elements of the pedals, dashboards, elements of seats, steering wheels, wheel bands, oil sumps, elements and housings of the gearbox, framing of doors and sunroofs, and others, etc. Originality/value: Contemporary materials should possess high mechanical properties, physical and chemical, as well as technological ones, to ensure long and reliable use. The above mentioned requirements and expectations regarding the contemporary materials are met by the non-ferrous metals alloys used nowadays, including the magnesium alloys.
At the contemporary stage of the development of the engineering thought, and the product technology itself, material engineering has entered the period of new possibilities of designing and manufacturing of elements, introducing new methods of melting, casting, forming, and heat treatment of the casting materials, finding wider and wider applications in many industry branches. Therefore the development of engineering aims at designs optimizing, reducing dimensions, weight, and extending the life of devices as well as improving their reliability [1-3]. Contemporary materials should possess high mechanical properties, physical and chemical, as well as technological ones, to ensure long and reliable use. The above mentioned requirements and expectations regarding the contemporary materials are met by the non-ferrous metals alloys used nowadays, including the magnesium alloys. Magnesium alloys and their derivatives, characterize of low density (1.5-1.8 g/cm3) and high strength in relation to their weight [1,3]. Knowledge of the relaxation properties of metal materials at elevated temperatures is necessary for the verification of susceptibility of castings to the creation of defects during the production and forming processes [1,4]. Temperature limits of materials where highest tension values are generated may be detected with tensile tests under high temperatures. Experimental investigation was made on magnesium alloy AZ91 - samples A and AZ61 - samples B (after ASTM Standard) in initial state as cast. The purpose of the measurement was the study of deformation and tension changing with temperature at the tensile test and in time with simultaneous acoustic emission (AE) measurement (in the case of alloy AZ61). These dependencies were also monitored at various temperatures of sample heating from 15°C to 400°C with crosspiece shift of 6mm/min. The measurement included material sample stress at the given temperature by tension at the INOVA electro hydraulic loading machine with a loading force of 20 kN with possibility of the acoustic emission (AE) monitoring. The test bar with 0 4 mm was warmed up in a graphite furnace in inert atmosphere (argon). The AE scanner records released elastic waves (overshoots) in a frequency band between 30 kHz and 400 kHz. The output from the scanner is carried to the AE preamplifier where it is amplified and impedance-adjusted so it is possible to be transferred to more far-reaching places. The signal is further carried to the EMIS 01 system and to the PC's hard disk and they are processed in the EXCEL. Microstructure of the alloys in initial state is formed by solid solution and by minority phases Mgn(Al,Zn)i2 in massive and dispersion form and showed dendritic segregation. During heating magnesium alloy AZ91 at chosen temperatures there occurs partial dissolution of minority phases. Homogenisation of microstructure is, however, accompanied by simultaneous forming of inter-granular non-integrities, which is unfavourable from the viewpoint of strength and plastic properties, especially at higher temperatures. Failure occurs practically at all temperatures basically by inter-crystalline splitting along the boundaries of original dendrites. Trans-crystalline plastic character of fracture in small areas at 300°C was occurred. Similar temperature dependence was occurred in the case of alloy AZ61. In this case the plasticity properties were at high level. An acoustic emission method was used for a better analysis of the course of the deformation action at the tensile test. The AE method especially enables a study of dynamics of these processes at various temperatures. The opportunity to study deformation processes preceding initiation of cracks and monitoring of initiation and crack growth as up to the macroscopic scale is a big advantage of the AE. The method is therefore used in the technical diagnostics and at a check of technological operations in the production process.
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Purpose: Magnesium alloys are the very progressive materials whereon is due to improve their end-use properties, which. Especially, wrought Mg alloys attract attention since they have more advantageous mechanical properties than cast Mg alloys. Design/methodology/approach: The presented article shows some specific physical-metallurgical characteristics of magnesium alloys of the AZ91 kind after hot forming. Special attention has been focused on the analysis of mutual relations existing between the deformation conditions, microstructural parameters, and the achieved mechanical properties. Findings: The discussed topic includes namely the monitoring of the structures in the initial cast state and after the heat treatment of the T4 kind and the influence of rolling in hot state at different temperatures on this structure. The results of torsion tests of AZ91, AZ61 and AZ31 were added. Research limitations/implications: The results of this paper evinces that a combination of ECAP technology with conventional rolling is very effective tool for improve a final properties of magnesium alloys in practical use. Practical implications: It would be appropriate a extrusions processes for increasing of mechanical properties on their treatment by plastic deformations in a rolling mills. Originality/value: It is explained a big consequence of the ECAP integration between classical forming techniques.
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Purpose: The purpose of the paper is the verification of functionality of the ECAP technology at extrusion of the copper, alluminium alloys, magnesium alloys and steel. Design/methodology/approach: Deformation forces were measured during extrusion, resistance to deformation was calculated and deformation speed was determined approximately. Analysis of structure was made with use of light microscopy and TEM. Findings: The samples of Cu and Al alloys were extruded at room temperature. For the samples of steel and AZ91 alloy was used the two-stage pressing, when the samples were extruded at temperature of approx. T1=325*C and T2=220*C. In order to increase concentration of deformation in volume of the sample the samples were after individual passes turned around their longitudinal axis by 90° and extruded again. Practical implications: Experiments on poly-crystalline copper of the grade C10200, aluminium alloy AlCu2.5Mg and steel P355Q confirmed that the ECAP method is efficient tool for refining of grain. Originality/value: Cross-section of original samples of Cu and Al alloys was 8 x 8 mm and their length was 32 mm and cross-section of original samples of steel and AZ 91 alloy was 10 x 10 mm and their length was 40 mm.