擠製態Al-4.8Zn-1.8Mg合金熱變形行為及加工圖研究

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林俊男(Chun-Nan Lin) 查詢紙本館藏

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擠製態Al-4.8Zn-1.8Mg合金熱變形行為及加工圖研究
(Study of hot deformation behavior and processing maps for as-extruded Al-4.8Zn-1.8Mg alloys)

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摘要(中)

鋁合金熱壓縮行為研究的文章多使用均質態的鑄坯，其晶粒為等軸晶；然而針對商業鋁合金鍛造所使用的坯件狀態多為擠製態，其晶粒為已具備應變能之細長條狀；上述兩種坯件在熱壓縮過程的變形行為勢必有所差異。為了提供鍛造製程工程師和模具設計師更接近實際鍛造行為的微結構變化，本論文以擠製態7005鋁合金(Al-4.8Zn-1.8Mg)為研究對象，進行等溫熱壓縮試驗(溫度300-550oC，應變速率0.001-1s-1，應變量1.2)。
比較試件在壓縮前後不同條件之巨觀結構與微觀結構演化，壓縮前的試片晶粒組織呈現細長條狀，細部放大可看到部分具等軸晶外型的再結晶晶粒。除了壓縮溫度550oC以外，其餘條件壓縮後的試片從巨觀結構可看到試件內部依受力狀況以及變形狀況不同可區分為三個區域，分別為難變形區(應變量最小)、容易變形區(應變量最大)、自由變形區(應變量居中)。而從EBSD微觀結構看出提高變形溫度以及降低應變速率較容易驅動動態回復以及動態再結晶使流變應力降低。根據晶粒方向差角判斷可發現，擠製態7005鋁合金之動態再結晶粒依形成過程之差異可分為連續動態再結晶、不連續動態再結晶以及幾何動態再結晶；後兩者形成位置為沿著原始晶界。
本研究根據動態材料模型(DMM)，求出功率耗散效率(η)與失穩值(ξ)，建構包含真應變量在內的三維度(3D)擠製態7005合金熱加工圖(processing maps)；並搭配微觀結構選出最佳製程區間。結果顯示，η值隨溫度或應變量的增加而增加，但隨應變速率的增加而遞減。失穩區的範圍隨溫度的降低或應變速率的增加而擴展。η<0.20通常位於失穩區，可發現Micro crack及Flow localization等微觀缺陷；而穩定區的微觀組織為晶粒細小之再結晶晶粒，η值皆在0.30以上。最佳製程區間為加工溫度425–500度C，應變速率0.1～0.01s-1。最後，本研究將η值與ξ值結合數值模擬並率先應用在車輪轂閉模鍛造參數最佳化分析，使商業鍛造模擬軟體具有預測微觀結構演變的功能，簡化模具設計與決定製程參數時的試驗流程。

摘要(英)

The billets commonly utilized in the commercial forging of aluminum alloys are typically in an extruded state, characterized by elongated grains containing pre-existing strain energy. However, numerous studies examining the hot compression behavior of aluminum alloys often employ homogeneous cast ingots with equiaxed grains. It is anticipated that the deformation behaviors of these two types of billets during the hot compression process will differ. In order to offer process engineers and mold designers with microstructural changes that closely reflect actual deformation behaviors, this study concentrates on the extruded state of 7005 alloys (Al-4.8Zn-1.8Mg), conducting isothermal compression tests within a temperature range of 300-550°C, strain rates of 0.001-1s-1, and a strain of 1.2.
In comparing the evolution of macrostructure and microstructure of specimens under various conditions before and after compression, it was observed that pre-compressed samples displayed elongated grains, with some recrystallized grains exhibiting an equiaxed shape upon closer examination. Post-compression specimens under conditions other than a compression temperature of 550°C exhibited three distinct regions in the macrostructure characterized by internal stress and deformation: a hard-to-deform zone with minimal strain, an easily deformable zone with maximal strain, and a free deformation zone with mid-range strain. Microstructure analysis using Electron Backscatter Diffraction (EBSD) indicated that higher deformation temperatures and lower strain rates promoted dynamic recovery and dynamic recrystallization, leading to a reduction in flow stress. Examination of grain misorientation revealed that dynamically recrystallized grains in as-extruded 7005 alloys could be classified into continuous dynamic recrystallization, discontinuous dynamic recrystallization, and geometric dynamic recrystallization, with the latter two processes occurring along the original grain boundaries.
In this investigation, the Dynamic Material Model (DMM) is being employed to analyze the power dissipation efficiency (η) and instability value (ξ) using data derived from hot compression tests in order to construct a three-dimensional (3D) processing map for as-extruded 7005 alloys, incorporating true strain. Microstructure analysis was utilized to determine the optimal processing range. Findings reveal that η rises with temperature or strain yet declines with increasing strain rate. The region of instability expands with decreasing temperature or increasing strain rate. η values below 0.20 are typically in the instability region, linked to micro-defects like microcracks and flow localization. Conversely, in stable regions characterized by refined recrystallized grains, η values consistently exceed 0.30. The ideal processing range is temperatures from 425-500oC and strain rates between 0.1 and 0.01 s-1. This study is pioneering in optimizing closed die forging processing parameters by integrating power dissipation efficiency (η) and instability value (ξ) with numerical simulations. It introduces a predictive model for microstructure evolution through commercial simulation software, intending to enhance efficiency in trial processes for mold designers and forging engineers.

關鍵字(中)

★ 擠製態7005合金
★ 熱變形行為
★ 三維度加工圖
★ 有限元素數值模擬
★ 動態回復
★ 動態再結晶

關鍵字(英)

★ As-extruded 7005 alloys
★ Hot deformation behavior
★ 3D processing maps
★ FEM numerical simulation
★ Dynamic recovery
★ Dynamic recrystallization

論文目次

Table of contents
中文摘要.................................................i
ABSTRACT..............................................iii
Table of contents.......................................v
List of Figures......................................viii
List of Tables..........................................x
Explanation of Symbols.................................xi
1 Introduction....................................1
1.1 Background..........................................1
1.2 Literature survey...................................2
1.2.1 Hot deformation behavior and microstructure evolution on aluminum alloy.......................................2
1.2.2 Processing maps of Al-Zn-Mg series aluminum alloys ........................................................6
1.2.3 Integration of Processing Maps with FEM Numerical Simulation..............................................8
1.3 Simulation tests for hot forging processes.........10
1.3.1 Fundamental concepts of physical simulation......10
1.3.2 Materials and hot processing physical simulation testing machine........................................11
1.3.3 Isothermal hot compression test..................12
1.4 Hot compression processing deformation and softening mechanisms.............................................13
1.4.1 Dynamic recovery:................................14
1.4.2 Types and formation mechanisms of dynamic recrystallization......................................16
1.5 Analysis method of hot workability.................19
1.6 Research motivation, purpose, and content..........23
2 Experimental procedure.........................27
2.1 Preparation of isothermal compression test specimens...............................................27
2.1.1 Preparation of 7005 cast ingots...................27
2.1.2 Preparation of as-extruded 7005 alloys specimens..28
2.2 As-extruded 7005 alloys isothermal compression test.29
2.2.1 Introduction of Gleeble 3500 thermomechanical simulator...............................................29
2.2.2 As-extruded 7005 alloys isothermal compression test procedures..............................................30
2.3 Test piece preparation and observation equipment....33
2.3.1 OM inspection.....................................33
2.3.2 Electron Back-Scattered Diffraction (EBSD) Analysis................................................34
2.4 Parameter configuration for numerical simulation software................................................35
3 Microstructure evolution........................37
3.1 Comparison of homogenized and extruded microstructures.........................................37
3.2 As-extruded bar microstructure......................38
3.3 Macroscopic view of deformed specimens..............39
3.4 Microstructure of compressed specimens..............41
3.5 Influence of processing temperature on the microstructure of as-extruded 7005 alloys...............43
3.6 Influence of strain rate on the microstructure of as-extruded 7005 alloys....................................49
3.7 Analysis of dynamic recrystallization mechanisms....55
3.8 Correlation between the Z-parameter and the microstructure of as-extruded 7005 alloys...............58
3.9 Z-parameter simulation analysis by finite element method (FEM)...................................................62
4 As-extruded 7005 alloy processing maps..........65
4.1 Establishing hot processing map.....................65
4.2 Three-dimensional power dissipation maps analysis...69
4.3 Three-dimensional instability maps analysis.........73
4.4 Hot processing map analysis.........................74
4.5 Microstructural analysis with hot processing maps...76
4.6 Optimal processing window...........................79
4.7 Integration of processing map analysis results into FEM numerical simulation....................................83
5. Conclusions..........................................89
Reference...............................................91
Appendix 1 True stress-strain curves of the hot as-extruded 7005 alloy.............................................97
Appendix 2 博士候選人發表之期刊論文.......................98

List of Figures
Figure 1.1 True stress-true strain diagram. 14
Figure 1.2 Schematic of dynamic recovery. 15
Figure 1.3 Schematic of the continuous dynamic recrystallization. 18
Figure 1.4 Schematic of the geometric dynamic recrystallization. 19
Figure 1.5 X12CrMoWVNbN10-1-1 alloy power dissipation maps with different strains: (a)ε=0.2; (b)ε=0. 3; (c)ε=0. 4; (d)ε=0.5. 21
Figure 1.6AA7020 aluminum alloy 3D instability maps 22
Figure 1.7 Processing maps for the extruded 2195 Al-Li alloy are presented under strains of (a) 0.3, (b) 0.5, (c) 0.7, and (d) 0.9 23
Figure 2.1 Preparation process of cylindrical specimen. 28
Figure 2.2 Cross-section of 7005 alloy specimen in extruded state. 29
Figure 2.3 Schematic of the compression tests 31
Figure 2.4 FEM numerical simulation of the hot compression test. 36
Figure 2.5 FEM numerical simulation of automobile wheel hub forging forming process. 36
Figure 3.1(a) Homogeneous 7005 alloys OM image; 2(b) OM image. 38
Figure 3.2 LOM images: (a) Panoramic view, (b)Low-magnification view (c) Further magnification of the red box in Figure 4(b) 39
Figure 3.3 (a) Simulation of strain distribution, (b) schematic of the non-uniformity of the compressed sample. 40
Figure 3.4 Panorama views of hot compressed s at a strain rate 0.001 s – 1. 42
Figure 3.5 OM images of Region II (central region) 43
Figure 3.6 EBSD maps at a strain rate of 1 s⁻¹. 47
Figure 3.7 Recrystallization proportions at a strain rate of 1 s⁻¹. 48
Figure 3.8 Correlation between migration rate and temperature during deformation. 49
Figure 3.9 EBSD maps at various deformation rates and temperatures. 52
Figure 3.10 Recrystallization proportions at various deformation rates and temperatures. 53
Figure 3.11 Misorientation angle distribution histograms at various temperatures and strain rates 54
Figure 3.12 Simplified schematics for the three DRX process 57
Figure 3.13 DRX mechanism analysis by EBSD. 57
Figure 3.14 Relationships between (a) lnέ and σ; (b) lnέ and lnσ; (c) lnέ and ln[sinh(ασ)]; (d) ln[sinh (ασ)] and 1000/T. 59
Figure 3.15 Contours of lnZ. 61
Figure 3.16 Microstructures at different lnZ values. 61
Figure 3.17 Correlation between the Z-parameter and the microstructure by different parameters. 62
Figure 3.18 (a) numerical simulation of lnZ; (b) panoramic view. 63
Figure 4.1 Schematic of G content and J co-content 67
Figure 4.2 Cubic spline interpolation function fitting lnσ-lnε relationship curve: (a)ε=0.3;(b) ε=0.6; (c) ε=0.9; (d) ε=1.2 70
Figure 4.3 3D power dissipation maps (a) Sliced by temperature; (b) Sliced by ln (strain rate); and (c) Sliced by strain. 72
Figure 4.4 Power dissipation trend charts of as-extruded AA7005 alloys (a) by temperature effect; (b) by strain rate effect; and (c) by true strain effect. 73
Figure 4.5 3D instability map (a) Sliced by temperature; (b) Sliced by ln (strain rate) and (c) Sliced by strain. 74
Figure 4.6 Processing maps of different strains. 76
Figure 4.7 Microstructure of as-extruded 7005 alloys under different conditions with a strain of 1.2. 79
Figure 4.8 Microstructural evolution characteristics of as-extruded 7005 alloys under different process parameters 80
Figure 4.9 EBSD images under different conditions. 82
Figure 4.10 Grain size distribution and grain size average. 83
Figure 4.11 FEM simulation and OM observation result. 84
Figure 4.12 Simulation results of the dissipation efficiency distribution. 86
Figure 4.13 Histogram of simulation results of dissipation efficiency distribution. 86
Figure 4.14 Simulation results of instability values. 87

List of Tables
Table 1.1 Optimal process conditions for Al-Zn-Mg aluminum alloys 8
Table 2.1 Chemical compositions of the as cast 7005 alloys. (wt.%) 27
Table 2.2 Compression test condition 32

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指導教授

李勝隆(Shen g -Long Lee)

審核日期

2024-4-29

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