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A Novel Turning-Induced-Deformation Based Technique to Process Magnesium Alloys

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A Novel Turning-Induced-Deformation Based Technique to Process Magnesium Alloys metals Article A Novel Turning-Induced-Deformation Based Technique to Process Magnesium Alloys Sravya Tekumalla 1, Manasa Ajjarapu 2 and Manoj Gupta 1,* 1 Department of Mechanical Engineering, National University of Singapore, Singapore 117575, Singapore 2 Department of Mechanical Engineering, Sastra Deemed University, Tamilnadu 613401, India * Correspondence: [email protected]; Tel.: +65-6516-6358 Received: 9 July 2019; Accepted: 26 July 2019; Published: 29 July 2019 Abstract: A magnesium alloy was fabricated through the consolidation of chips accumulated during the turning process, followed by cold compaction and hot extrusion. A variation in the depths of cut was done during turning to understand the effect of deformation imparted during primary processing on the mechanical properties of an AZ91 alloy (Mg–9 wt.% Al–1 wt.% Zn–0.3 wt.% Mn). The results revealed a significant improvement in compressive strengths (up to 75%) with increased depth of cut, without compromising ductility through the development of fine-grained structures and prior plastic strain induction. This approach resulted in superior materials vis-a-vis conventional deformation techniques and promotes cost and energy efficiency through recycling industrial metal swarf, which is a significant environmental and economic concern. Keywords: magnesium; turning; deformation; processing; strength 1. Introduction For magnesium to replace the relatively heavier aluminum, titanium, and steels in structural applications, there are still several challenges that are persistent such as the inferior strength, ductility, corrosion resistance, etc. of magnesium [1]. Among the magnesium alloys, the most widely used commercial alloy AZ91 exhibits an excellent combination of mechanical properties, corrosion resistance, and cast ability [2]. However, improved strength is still needed to extend its applications. There have been several attempts made previously to improve its mechanical properties through altering the processing or modifying the alloy chemistry. The effectiveness of severe plastic deformation (SPD) techniques such as equal channel angular pressing (ECAP) to improve the mechanical properties of AZ91 alloy has been widely studied [3–5]. While this is a hot deformation technique, it was demonstrated that cold severe plastic deformation processes such as HPT (high pressure torsion) can render the AZ91 alloy superplastic [6]. Apart from these SPD techniques, effects of torsion deformation and ageing have also been studied [7] on age hardenable alloys such as the AZ91 alloy. It has been reported that this method was effective in reducing the yield asymmetry of the alloy, and deformation by torsion enhanced the effect of age-hardening that led to continuous precipitation, hence improving the mechanical properties of the alloy. Thus, significant enhancement of the properties can be achieved based on the extent of deformation introduced in the material. A majority of these deformation techniques are wrought techniques where the material undergoes secondary processing such as extrusion, rolling, or forging. In this work, the concept of deformation was used as an inspiration and applied as an extension to the primary processing to synthesize materials with better mechanical properties. In this regard, a novel approach of producing deformed material from chips/turnings obtained during the turning (machining) process followed by the conventional powder metallurgy of the turnings is proposed, as given in Figure1. Turning of a metal involves the removal of material in the form of chips/turnings through localized deformation as stated in [8]. This approach of inducing Metals 2019, 9, 841; doi:10.3390/met9080841 www.mdpi.com/journal/metals Metals 2019, 9, x FOR PEER REVIEW 2 of 9 Metals 2019, 9, 841 2 of 9 stated in [8]. This approach of inducing deformation is deemed to be an efficient form as it uses chips deformationthat are usually is deemed scrap formed to be an during efficient the form removal as it of uses material chips thatto obtain are usually the desired scrap geometry. formed during In the theUS, removal machining of materialand other to related obtain operations the desired accounts geometry. for an In expenditure the US, machining higher than and hundred other related billion operationsdollars ($100 accounts billion) for annually an expenditure [9]. Most higher machine than hundredtools (>80%) billion typically dollars used ($100 in billion) the manufacturing annually [9]. Mostindustry machine are metal tools (cutting>80%) typicallyin nature, used leading in the to manufacturinglarge volumes of industry metal swarf. are metal Recycling cutting these in nature, metal leadingwastes tocould large enhance volumes economic of metal swarf.profit and Recycling reduce these the environmental metal wastes could impact enhance of manufacturing economic profit (ore andmining reduce and the metal environmental refining to meet impact the of metal manufacturing stocks of global (ore mining demand and annu metalally) refining [10]. Furthermore, to meet the metaldue to stocks the excellent of global machinability demand annually) of most [magnes10]. Furthermore,ium based materials, due to the the excellent machining machinability of magnesium of mostcan be magnesium done via dry based cutting materials, where the the machining need for cutting of magnesium fluids or can lubricants be done is via eliminated dry cutting before where the therecycling need for operation, cutting fluids thus ormaking lubricants it an iseconomical eliminated process before the[11]. recycling Thus, this operation, work proposed thus making a novel, it anefficient, economical and processeconomic [11 approach]. Thus, this of workimproving proposed the mechanical a novel, effi cient,properties and economicof a magnesium approach alloy of improvingthrough a theturning-induced-deformation mechanical properties of a technique. magnesium Th alloye as-cast through ingots a turning-induced-deformation used in this work for turning technique.and the generation The as-cast of ingots chips used as several in this workdie cast for turningmagnesium and thealloys generation were machined of chips asto several obtain diethe castrequired magnesium dimensions alloys and were surface machined finish, to and obtain the themagnesium required swarf dimensions was generated and surface in this finish, process and [12]. the magnesiumAlthough previous swarf was works generated have been in this undertaken process [12 on]. Although the consolidation previous of works chips have (solid been state undertaken recycling) onof themagnesium, consolidation aluminum, of chips and (solid copper state [13,14], recycling) there of has magnesium, been no systematic aluminum, study, and copperto the authors’ [13,14], therebest hasknowledge, been no systematicon the properties study, to theof magnesium authors’ best alloy-based knowledge, chips, on the especially properties ofin magnesiumlight of the alloy-baseddeformation chips, imparted especially to inthe light material of the deformationbased on the imparted variation to the of material the machining based onthe parameters. variation ofFurthermore, the machining this parameters. work aimed Furthermore, to give direction this work to the aimed solid-state to give recycling direction toof thechips solid-state generated recycling not just ofthrough chips generated turning, but not through just through all machining turning, but processes through in all general. machining processes in general. Figure 1. Mechanism of this approach vs. ECAP (equal channel angular pressing). Figure 1. Mechanism of this approach vs. ECAP (equal channel angular pressing). 2. Materials and Methods 2. Materials and Methods 2.1. Processing 2.1. Processing In this study, AZ91 alloys, supplied by Tokyo Magnesium Co. Ltd. (Yokohama, Japan), were used asIn thethis basestudy, materials. AZ91 alloys, The AZ91supplied ingots by wereTokyo subjected Magnesium to a Co. turning Ltd. operation(Yokohama, performed Japan), were on aused lathe as machine the base at materials. 395 rpm andThe aAZ91 feed ingots rate of were 62 mm subjected/min. In to this a turning operation, operation a piece performed of material on in a thelathe form machine of chips at/ turnings395 rpm and was a removed feed rate from of 62 the mm/min. surfaces In of this the operation, work-piece a /pieceingot of using material a carbide in the insertform (TNMGof chips/turnings 160404-HQ; was Grade removed CA515, from Hare the surfaces & Forbes of machinerythe work-piece/ingot house, Sydney, using Australia)a carbide insert in a turning(TNMG tool 160404-HQ; holder (Model Grade No. CA515, WTJNR-2020-K16, Hare & Forbes Hare machinery & Forbes house, machinery Sydney, house, Australia) Sydney, in Australia) a turning withtool aholder tool height (Model of No. 20 mm. WTJNR-2 The parameter020-K16, Hare that varied & Forbes in the machinery turning operationhouse, Sydney, was the Australia) depth of with cut (DOC)a tool height where of the 20 ingots mm. The were parameter given three that di variedfferent in DOCs: the turning 0.5 mm operation DOC, 1.0was mm the DOC,depth andof cut 1.5 (DOC) mm DOC,where while the ingots all of were the other given parameters three different were DO keptCs: constant. 0.5 mm DOC, Compaction 1.0 mm of DOC, the collectedand 1.5 mm turnings DOC, waswhile done all of uniaxial the other at roomparameters temperature were kept in a consta hydraulicnt. Compaction press for a durationof the collected of 1 min turnings at a pressure was done of uniaxial at
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