On the Competition between Intergranular and Transgranular Failure within 7xxx Al Alloys with Tailored Microstructures.

7xxx aluminium series reach exceptional strength compared to other industrial aluminium alloys. However, 7xxx aluminium series usually exhibit Precipitate-Free Zones (PFZs) along grain boundaries, which favour intergranular fracture and low ductility. In this study, the competition between intergranular and transgranular fracture is experimentally investigated in the 7075 Al alloy. This is of critical importance since it directly affects the formability and crashworthiness of thin Al sheets. Using Friction Stir Processing (FSP), microstructures with similar hardening precipitates and PFZs, but with very different grain structures and intermetallic (IM) particle size distribution, were generated and studied. Experimental results showed that the effect of microstructure on the failure mode was significantly different for tensile ductility compared to bending formability. While the tensile ductility was significantly improved for the microstructure with equiaxed grains and smaller IM particles (compared to elongated grains and larger particles), the opposite trend was observed in terms of formability.

Study on Near-Net Forming Technology for Stepped Shaft by Cross-Wedge Rolling Based on Variable Cone Angle Billets.

Considering problems about concaves at the stepped shaft ends, this paper established the plastic flow kinetic theories about metal deforming during the cross-wedge rolling (CWR) process. By means of the DEFORM-3D finite element software and the point tracing method, the forming process of stepped shafts and the forming mechanism of concaves at shaft ends were studied. Based on the forming features of stepped shafts, rolling pieces were designed using variable cone angle billets. Single-factor tests were conducted to analyze the influence law of the shape parameters of billet with variable cone angle on end concaves, and rolling experiments were performed for verification. According to the results, during the rolling process of stepped shafts, concaves will come into being in stages, and the increasing tendency of its depth is due to the wave mode, the parameters of cone angle α, the first cone section length n. Furthermore, the total cone section length m has an increasingly weaker influence on the end concaves. Specifically, cone angle α has the most significant influence on the quality of shaft ends, which is about twice the influence of the total cone section length m. The concave depth will decrease at the beginning, and then increase with the increasing of the cone angle α and the first cone section length n, and it will decrease with the increasing of the total cone section length m. Finite element numerical analysis results are perfectly consistent with experimental results, with the error ratio being lower than 5%. The results provide a reliable theoretical basis for effectively disposing of end concave problems during CWR, rationally confirming the shape parameters of billets with a variable cone angle, improving the quality of stepped shaft ends, and realizing the near-net forming process of cross-wedge rolling without a stub bar.