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Friedrich-Alexander Universität Erlangen-Nürnberg, Studienarbeit (2004)

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Friedrich-Alexander Universität Erlangen-Nürnberg, Studienarbeit (2004) Ultrafine‐grained Metal Sheets produced using the Accumulative Roll Bonding Process for Light‐Weight Structures Der Technischen Fakultät der Universität Erlangen‐Nürnberg zur Erlangung des Grades DOKTOR‐INGENIEUR vorgelegt von Irena Topić Erlangen 2008 Herstellung von ultrafeinkörnigen Blechen mittels des kumulativen Walzprozesses für den Leichtbau Der Technischen Fakultät der Universität Erlangen‐Nürnberg zur Erlangung des Grades DOKTOR‐INGENIEUR vorgelegt von Irena Topić Erlangen 2008 Als Dissertation genehmigt von der Technischen Fakultät der Universität Erlangen‐Nürnberg Tag der Einreichung: 24.11.2008 Tag der Promotion: 15.04.2009 Dekan: Prof. Dr.‐Ing. Johannes Huber Berichterstatter: Prof. Dr. rer. nat. Mathias Göken Prof. Dr.‐Ing. Marion Merklein ABSTRACT Over the last decade, nanocrystalline and ultrafine-grained (UFG) materials with a grain size of less than 1 µm have aroused considerable interest due to their superior mechanical properties in terms of strength and/or ductility compared to conventionally grained materials. As such, they have a strong potential for prospective engineering applications for structural, high durability components in automobile, aerospace and medical industry. In this work, different materials such as commercial purity aluminium AA1050, aluminium alloy AA6016, oxygen free copper, titanium and niobium were processed by the Severe Plastic Deformation (SPD) technique called Accumulative Roll Bonding (ARB) in order to produce an ultrafine- grained microstructure and improve the mechanical properties. One of the biggest advantages of the ARB process in comparison to other SPD methods such as Equal Channel Angular Pressing (ECAP) or High Pressure Torsion (HPT) is that it is a continuous process, which can be incorporated in industry to produce large scale UFG metal sheets. During the ARB process, the metal sheet surfaces are wire brushed in order to remove the oxide layer, stacked on top of each other and rolled together with a thickness reduction of 50 %. The metals sheets bond together during rolling and the procedure can then be repeated any number of times. The material is subjected to very high plastic, shear deformation and the UFG microstructure starts to develop after approximately 4 ARB cycles. This study focuses primarily on the ARB processed commercial purity aluminium AA1050 and the technically relevant aluminium alloy AA6016. Ultrafine-grained Al metal sheets are especially interesting for light weight construction in the automobile industry due to their high specific strength. In order to qualify the accumulative roll bonding process for these purposes detailed investigations on microstructural evolution, mechanical properties and sheet metal forming using bulge tests and cup drawing tests have been carried out and investigated. Sheet metal joining is one further technologically important issue, which places a challenge upon UFG aluminium sheet materials. Friction Stir Welding (FSW) was found to be a desirable joining technique for UFG materials, since it provides excellent mechanical properties and retains the fine grained microstructure. During the course of this study, the ARB process was adapted and optimised for every materials system and the quality of the sheets was improved. The ARB process was significantly shortened and it became more robust. The deformation during rolling became more homogeneous, cracking of the edges was eliminated and crack propagation was suppressed. These factors cumulatively contributed to less material waste during the process. The quality of the surface was considerably improved and the sheet thickness became more homogeneous. The contribution of a four-high rolling mill was especially manifested in terms of the final width of metal sheets. Irrespective of the process parameters, rapid grain refinement and significantly higher hardness and strength with increasing number of ARB cycles, in comparison to the CG counterpart were observed for all materials. The ARB processed materials are microstructurally anisotropic and they develop a characteristic ß-fibre texture with a Cu component. UFG Al sheets showed promising sheet metal forming potential under biaxial stress state conditions and under tension-compression conditions, which occur during cup drawing experiments. Generally, UFG aluminium samples rolled up to 4 ARB cycles showed a good compromise between strength, elongation to failure, minimal sheet thinning and earing during deep drawing cup tests. However, deep drawing cup tests showed that the metal sheet formability significantly increases at elevated temperatures. Furthermore, the UFG materials confirmed that their enhanced strain rate sensitivity can be advantageously used in order to achieve higher formability. The UFG AA1050 and AA6016 sheets were successfully friction stir welded. Although a drop in hardness is measured in the nugget for both materials, the hardness is comparable to that of the CG counterparts and is not considered to be a technological limitation. However, bulge tests and cup drawing tests both confirmed limited formability, which appears to be governed by the amount of deformation and strength of the nugget. Even though there is still very limited amount of research regarding the formability and direct applications of UFG sheets, their potential should not be underestimated. The production of UFG materials can become commercialised and cost effective, and it could become possible to control the mechanical properties of materials by processing rather than by alloying. In the meantime, the big technical potential of ARB processed materials was also recognised by the aluminium manufacturers. Future interests are closely related to superplastic forming, accumulative roll bonding of magnesium alloys for lightweight structural components, as well as accumulative roll bonding of IF-steel. Thus, the innovation potential of the UFG materials for advanced applications in engineering is high, and the requirements for producing such materials are becoming more and more economically feasible. KURZFASSUNG In den letzten Jahren ist das Interesse an nanokristallinen und ultrafeinkörnigen Werkstoffen enorm gestiegen. Ultrafeinkörnige (engl.: ultrafine-grained UFG) Werkstoffe mit einer Korngröße von etwa 100 nm bis 1000 nm besitzen außergewöhnliche und für die technische Anwendung vielversprechende mechanische Eigenschaften im Vergleich zu Werkstoffen mit konventioneller Korngröße. Durch die hohe spezifische Festigkeit haben UFG-Werkstoffe insbesondere im Bereich der Konstruktionswerkstoffe und des Leichtbaus ein großes Anwendungspotenzial. Im Rahmen dieser Arbeit wurden verschiedene Werkstoffen konventioneller Korngröße wie technisch reines Aluminium (AA1050), die Aluminiumlegierung AA6016, hochreines Kupfer, Titan und Niob mit dem sogenannten kumulativen Walzprozess (engl.: Accumulative Roll Bonding ARB) umgeformt. Mit diesem Verfahren lassen sich hauptsächlich flächige Bauteile mit ultrafeinkörnigen Mikrostrukturen erzeugen. Einer der größten Vorteile dieses Prozesses im Vergleicht zu den anderen Hochverformungsprozessen wie z.B. Equal Channel Angular Pressing (ECAP) oder High Pressure Torsion (HPT), ist dass er verhältnismäßig leicht in bestehende Walzanlagen integriert werden kann und so großflächige ultrafeinkörnige Bauteile hergestellt werden können. Grundlage des ARB-Prozesses ist es, dass ein Blechwerkstoff wiederholt einer Walzverformung (Scherverformung) unterzogen wird. Um den Prozess hinreichend häufig durchführen zu können, wird nach jedem Walzdurchgang mit einer Stichabnahme von 50 % das Blech in der Länge halbiert. Nach dem Drahtbürsten zur Beseitigung der Oberflächenoxide und Erzeugung einer entsprechend aufgerauten Oberfläche werden beide Blechstreifen wieder aufeinander gelegt und fixiert. Der Walzschritt wird dann von neuem ausgeführt. Während des Walzvorgangs erfolgt dabei ein Verbinden der beiden Blechlagen. Durch Wiederholung dieses Vorgangs kann nach einer hinreichend großen Anzahl an ARB- Zyklen eine ultrafeinkörnige Mikrostruktur mit einer Korngröße im Bereich von einigen hundert Nanometern erreicht werden. Der Schwerpunkt dieser Arbeit lag auf der Herstellung von UFG technisch reinem Aluminium (AA1050) und Aluminiumlegierung AA6016. Die ultrafeinkörnigen Aluminiumbleche sind auf Grund ihrer hohen spezifischen Festigkeit von besonderem Interesse im Bereich des Leichtbaus. Um den ARB Prozess als ein modernes Herstellungsverfahren für die UFG Bleche zu qualifizieren, wurden detaillierte Untersuchungen der Mikrostruktur, mechanischen Eigenschaften und Umformverhalten wie z.B. Tiefungsversuche und Napfziehversuche durchgeführt. Zur Herstellung großflächiger Bauteile in der technologischen Anwendung war es außerdem notwendig, geeignete Fügeverfahren hinsichtlich ihrer Auswirkungen auf die mechanischen Eigenschaften zu untersuchen. Im laufe der Arbeit hat sich gezeigt, dass das Reibrührschweißen ein geeignetes Verfahren für das Fügen von UFG Aluminium-Blechwerkstoffe darstellt. Die feinkörnige Mikrostruktur wurde während des Reibrührschweißens beibehalten und der Prozess führte zu ausgezeichnete mechanische Eigenschaften der UFG-Bleche. Durch gezielte Untersuchungen gelang es zunächst, sowohl die ARB-Prozesskette zu optimieren, als auch die erzielbare Blechqualität deutlich zu verbessern. Mit der Anschaffung eines Quartowalzgerüstes, konnte im Vergleich zur Duowalze eine homogenere Materialverformung bei gleichzeitig geringerer Rißanfälligkeit im Randbereich erreicht werden. Insgesamt führte dies zu weniger
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