Acta Metallurgica Sinica (English Letters) ›› 2017, Vol. 30 ›› Issue (5): 409-432.DOI: 10.1007/s40195-017-0565-8
Special Issue: 2016-2017铝合金专辑; 2017-2018铝合金专辑
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Received:
2016-10-08
Revised:
2017-03-01
Online:
2017-05-20
Published:
2017-05-23
About author:
These authors contributed equally to this work.
Ren-Guo Guan, Di Tie. A Review on Grain Refinement of Aluminum Alloys: Progresses, Challenges and Prospects[J]. Acta Metallurgica Sinica (English Letters), 2017, 30(5): 409-432.
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Date | Severe plastic deformation | Grain refiner | Rapid solidification | Vibration and stirring |
---|---|---|---|---|
2000 years ago | Multi-directional forging | |||
1857 | Twin-roll casting [ | |||
1870s | Mechanical vibration [ | |||
1920s | High-pressure die casting [ | |||
1930s | Ultrasonic vibration [ | |||
1937 | Liquid forging technique [ | |||
1941 | Gas atomization [ | |||
1947 | Electromagnetic stirring [ | |||
1950s | Al-Ti-B [ | |||
1958 | Melt spinning [ | |||
1968 | Spray deposition [ | |||
1977 | Equal-channel angular pressing [ | |||
1979 | Cyclic extrusion-compression [ | |||
1980s | Al-Ti-C [ | |||
1989 | High-pressure torsion [ | |||
1991 | Friction stir welding [ | |||
1996 | Cooling slope [ | |||
1998 | Accumulative roll-bonding [ | |||
1999 | Twist extrusion [ | |||
2001 | Repetitive corrugation and straightening [ | |||
2007 | Vibrating cooling slope [ | |||
2014 | Tube cyclic extrusion [ | |||
2015 | Accumulative continuous extrusion forming [ |
Table 1 Development of grain refinement methods
Date | Severe plastic deformation | Grain refiner | Rapid solidification | Vibration and stirring |
---|---|---|---|---|
2000 years ago | Multi-directional forging | |||
1857 | Twin-roll casting [ | |||
1870s | Mechanical vibration [ | |||
1920s | High-pressure die casting [ | |||
1930s | Ultrasonic vibration [ | |||
1937 | Liquid forging technique [ | |||
1941 | Gas atomization [ | |||
1947 | Electromagnetic stirring [ | |||
1950s | Al-Ti-B [ | |||
1958 | Melt spinning [ | |||
1968 | Spray deposition [ | |||
1977 | Equal-channel angular pressing [ | |||
1979 | Cyclic extrusion-compression [ | |||
1980s | Al-Ti-C [ | |||
1989 | High-pressure torsion [ | |||
1991 | Friction stir welding [ | |||
1996 | Cooling slope [ | |||
1998 | Accumulative roll-bonding [ | |||
1999 | Twist extrusion [ | |||
2001 | Repetitive corrugation and straightening [ | |||
2007 | Vibrating cooling slope [ | |||
2014 | Tube cyclic extrusion [ | |||
2015 | Accumulative continuous extrusion forming [ |
Type | Advantages | Disadvantages |
---|---|---|
F-EMS | Low central loose, low shrinkage cavity and central segregation (especially V-shaped segregation) | Only working at low frequency is effective |
M-EMS | High surface quality, excellent microstructure of product, high casting speed | Strict requirement of device |
S-EMS | No central loose, low shrinkage cavity, low center segregation | No evident effect when this method is used independently |
Combined-EMS | High casting quality, low center segregation | Difficult to control the strength and direction of electromagnetic force |
Table 2 Classification of electromagnetic stirring
Type | Advantages | Disadvantages |
---|---|---|
F-EMS | Low central loose, low shrinkage cavity and central segregation (especially V-shaped segregation) | Only working at low frequency is effective |
M-EMS | High surface quality, excellent microstructure of product, high casting speed | Strict requirement of device |
S-EMS | No central loose, low shrinkage cavity, low center segregation | No evident effect when this method is used independently |
Combined-EMS | High casting quality, low center segregation | Difficult to control the strength and direction of electromagnetic force |
Vibration frequency | Application | Advantages | Problems | |
---|---|---|---|---|
Mechanical vibration | Less than 200 Hz | Continuous casting | Fine grain; uniform composition; the feeding efficiency can be improved; stable casting process | Thermal fragment tendency can be increased; large pores may produce at high frequency |
Ultrasonic vibration | More than 20 kHz | Continuous casting, semi-continuous casting | Remarkable grain refining efficiency; macro-segregation and pore can be reduced; no pollution to melt; low segregation | Lack of high-power ultrasonic equipment and high-frequency vibration resistance of ultrasonic rod |
Table 3 Comparison of mechanical vibration and ultrasonic vibration
Vibration frequency | Application | Advantages | Problems | |
---|---|---|---|---|
Mechanical vibration | Less than 200 Hz | Continuous casting | Fine grain; uniform composition; the feeding efficiency can be improved; stable casting process | Thermal fragment tendency can be increased; large pores may produce at high frequency |
Ultrasonic vibration | More than 20 kHz | Continuous casting, semi-continuous casting | Remarkable grain refining efficiency; macro-segregation and pore can be reduced; no pollution to melt; low segregation | Lack of high-power ultrasonic equipment and high-frequency vibration resistance of ultrasonic rod |
Rapid solidification method | Cooling rate (K/s) |
---|---|
Water quenching [ | 102-103 |
Copper mold casting [ | 102-103 |
Twin-roll casting [ | 102-103 |
High-pressure die casting [ | 102-103 |
Liquid forging technique [ | 300-400 |
Gas atomization [ | 102-104 |
Melt spinning [ | 103 |
Spray deposition [ | 103-105 |
Cooling slope [ | 102-103 |
Vibrating cooling slope | 10-360 |
Table 4 Cooling rates of different solidification methods
Rapid solidification method | Cooling rate (K/s) |
---|---|
Water quenching [ | 102-103 |
Copper mold casting [ | 102-103 |
Twin-roll casting [ | 102-103 |
High-pressure die casting [ | 102-103 |
Liquid forging technique [ | 300-400 |
Gas atomization [ | 102-104 |
Melt spinning [ | 103 |
Spray deposition [ | 103-105 |
Cooling slope [ | 102-103 |
Vibrating cooling slope | 10-360 |
Invention time | Types of twin-roll casting | Advantages | Disadvantages |
---|---|---|---|
1857 [ | Twin-roll casting | Short process, low energy consumption | Low surface finish, limited types of alloys |
1960 [ | 3C twin-roll casting | Simple equipment structure, high reliability, low cost; suitable for soft alloy | Limited types of alloys |
1962 [ | Inclined twin-roll casting | Excellent product performance | Difficult roll replacing |
1985 [ | Unequal diameter twin-roll casting | Big freezing zone, wide alloy types, excellent product performance | Complicated technical parameters |
2012 [ | Twin-roll semisolid casting | Short process, low energy consumption, excellent product performance | Limited types of alloys |
Table 5 Comparison of different twin-roll casters
Invention time | Types of twin-roll casting | Advantages | Disadvantages |
---|---|---|---|
1857 [ | Twin-roll casting | Short process, low energy consumption | Low surface finish, limited types of alloys |
1960 [ | 3C twin-roll casting | Simple equipment structure, high reliability, low cost; suitable for soft alloy | Limited types of alloys |
1962 [ | Inclined twin-roll casting | Excellent product performance | Difficult roll replacing |
1985 [ | Unequal diameter twin-roll casting | Big freezing zone, wide alloy types, excellent product performance | Complicated technical parameters |
2012 [ | Twin-roll semisolid casting | Short process, low energy consumption, excellent product performance | Limited types of alloys |
Invention time | Types of spray deposition | Advantages | Disadvantages |
---|---|---|---|
1968 [ | Spray deposition | Fine grain, uniform composition | Complicated equipment, high porosity, limited product size |
1984 [ | Liquid dynamics compaction | Low inclusion and oxidation | High microporosity |
1988 [ | Spray co-deposition | Metal matrix composites can be prepared, uniform particle distribution, good bonding of particle and matrix, low oxidation, wide range of application | Complicated technical parameters |
1988 [ | Reactive spray forming | Metal matrix composites can be prepared in situ, particle size can be controlled, low cost | Complicated material composition, impurity |
Table 6 Comparison of different spray deposition methods
Invention time | Types of spray deposition | Advantages | Disadvantages |
---|---|---|---|
1968 [ | Spray deposition | Fine grain, uniform composition | Complicated equipment, high porosity, limited product size |
1984 [ | Liquid dynamics compaction | Low inclusion and oxidation | High microporosity |
1988 [ | Spray co-deposition | Metal matrix composites can be prepared, uniform particle distribution, good bonding of particle and matrix, low oxidation, wide range of application | Complicated technical parameters |
1988 [ | Reactive spray forming | Metal matrix composites can be prepared in situ, particle size can be controlled, low cost | Complicated material composition, impurity |
Theory | Positive viewpoints | Negative viewpoints |
---|---|---|
The carbide-borides theory [ | TiB2 is observed in Al grain The Al-Ti-B master alloy shows a better grain refinement effectiveness than Al-Ti alloy | Al-TiB2 master alloy has no grain refinement to high pure Al. But Al-Ti alloy has grain refinement effectiveness to high pure Al The carbide (or borides) has no grain refinement in the absence of solute Ti |
The peritectic theory [ | The refinement behaviors by Al-Ti series alloys are explained This theory is reasonable in Al alloy melt contain TiAl3 TiAl3 is observed at the center of the Al grain | This theory cannot explain the invigorating effect of B element on grain refinement The amount of free Ti is much lower than the Ti level required for peritectic reaction The TiAl3 phase is not thermodynamically stable for the peritectic reaction |
The peritectic hulk theory [ | TiAl3 phase is stable even at lower concentration in case of B addition The refinement behavior by Al-Ti-B (Ti/B > 2.22) is explained by the duplex nucleation theory | The boron has no effect on the Al-Ti phase diagram and stability of TiAl3 The grain refinement by Al-Ti-B refiner fades with the prolongation of holding time, but this fading disappears after stirring |
The duplex nucleation theory (the hypernucleation theory) [ | The existence of a Ti-rich layer on the surface of TiB2 | The thin phase between TiB2 and amorphous Al is difficult to identify In theory, pure Al, the mixture of Al and Al3Ti, or an intermediate Al-Ti structure all can nucleate on the surface of TiB2 particle |
The solute theory [ | Solute element has an effect on the growth restriction of grain The increased solute contents induce increased nucleation | The restrictive effect of solute element has a negligible influence on nucleation behavior and final grain size |
Table 7 Arguments of different theories on mechanism of grain refinement by grain refiner
Theory | Positive viewpoints | Negative viewpoints |
---|---|---|
The carbide-borides theory [ | TiB2 is observed in Al grain The Al-Ti-B master alloy shows a better grain refinement effectiveness than Al-Ti alloy | Al-TiB2 master alloy has no grain refinement to high pure Al. But Al-Ti alloy has grain refinement effectiveness to high pure Al The carbide (or borides) has no grain refinement in the absence of solute Ti |
The peritectic theory [ | The refinement behaviors by Al-Ti series alloys are explained This theory is reasonable in Al alloy melt contain TiAl3 TiAl3 is observed at the center of the Al grain | This theory cannot explain the invigorating effect of B element on grain refinement The amount of free Ti is much lower than the Ti level required for peritectic reaction The TiAl3 phase is not thermodynamically stable for the peritectic reaction |
The peritectic hulk theory [ | TiAl3 phase is stable even at lower concentration in case of B addition The refinement behavior by Al-Ti-B (Ti/B > 2.22) is explained by the duplex nucleation theory | The boron has no effect on the Al-Ti phase diagram and stability of TiAl3 The grain refinement by Al-Ti-B refiner fades with the prolongation of holding time, but this fading disappears after stirring |
The duplex nucleation theory (the hypernucleation theory) [ | The existence of a Ti-rich layer on the surface of TiB2 | The thin phase between TiB2 and amorphous Al is difficult to identify In theory, pure Al, the mixture of Al and Al3Ti, or an intermediate Al-Ti structure all can nucleate on the surface of TiB2 particle |
The solute theory [ | Solute element has an effect on the growth restriction of grain The increased solute contents induce increased nucleation | The restrictive effect of solute element has a negligible influence on nucleation behavior and final grain size |
Grain refiner | Al alloy | Average grain size after refinement (μm) | Holding time (min) | Holding temperature (°C) | Addition (wt%) |
---|---|---|---|---|---|
Ti [ | High-purity Al | 300 | 20 | 780 | 0.05 |
Cu [ | High-purity Al | 900 | 20 | 780 | 0.40 |
Mg [ | High-purity Al | 900 | 20 | 780 | 0.35 |
Al-5Ti-0.3C-0.2B [ | Commercial pure Al | 170 | 60 | 730 | 0.2 |
Al-1.12Ti-0.48B [ | Commercial pure Al | 156 | 2 | 720 | - |
Al-5Ti-1B [ | Commercial pure Al | 300 | 60 | 730 | 0.2 |
Al-3B [ | Commercial pure Al | 182 | 60 | 710 | 0.12 |
Al-Ti-C [ | Commercial pure Al | 189 | 60 | 720 | 0.2 |
Al-5Ti-1B (ultrasound) [ | Commercial pure Al | 45 | 15 | 730 | 2.5 |
Al-3B-5Sr [ | A356 | 300 | 30 | 720 | 0.5 |
Al-4Nb-1B [ | A356 | 300 | - | - | - |
Al-1Nb-1B [ | Al-12Si | 300 | - | - | - |
Al-2Nb-2B [ | Al-12Si | 400-500 | 30 | 740 | 5 |
Al-5Ti-0.75C [ | Al-5Cu | 50 | - | 720 | 2 |
Al-5Ti-0.25C [ | 6063 | 40 | 10 | 720 | 2 |
Al-5Ti-1B [ | 6063 | 40 | 10 | 720 | 3 |
Al-5Ti-1B [ | Al-12.24Zn-3.25Mg-2.46Cu-0.16Fe | 46 | 0.5 | 750 | 1 |
Al-5Ti-1B-0.1Er [ | Al-10Zn-1.9Mg-1.6Cu-0.12Zr | 40 | - | - | 1 |
Table 8 Different grain refiners
Grain refiner | Al alloy | Average grain size after refinement (μm) | Holding time (min) | Holding temperature (°C) | Addition (wt%) |
---|---|---|---|---|---|
Ti [ | High-purity Al | 300 | 20 | 780 | 0.05 |
Cu [ | High-purity Al | 900 | 20 | 780 | 0.40 |
Mg [ | High-purity Al | 900 | 20 | 780 | 0.35 |
Al-5Ti-0.3C-0.2B [ | Commercial pure Al | 170 | 60 | 730 | 0.2 |
Al-1.12Ti-0.48B [ | Commercial pure Al | 156 | 2 | 720 | - |
Al-5Ti-1B [ | Commercial pure Al | 300 | 60 | 730 | 0.2 |
Al-3B [ | Commercial pure Al | 182 | 60 | 710 | 0.12 |
Al-Ti-C [ | Commercial pure Al | 189 | 60 | 720 | 0.2 |
Al-5Ti-1B (ultrasound) [ | Commercial pure Al | 45 | 15 | 730 | 2.5 |
Al-3B-5Sr [ | A356 | 300 | 30 | 720 | 0.5 |
Al-4Nb-1B [ | A356 | 300 | - | - | - |
Al-1Nb-1B [ | Al-12Si | 300 | - | - | - |
Al-2Nb-2B [ | Al-12Si | 400-500 | 30 | 740 | 5 |
Al-5Ti-0.75C [ | Al-5Cu | 50 | - | 720 | 2 |
Al-5Ti-0.25C [ | 6063 | 40 | 10 | 720 | 2 |
Al-5Ti-1B [ | 6063 | 40 | 10 | 720 | 3 |
Al-5Ti-1B [ | Al-12.24Zn-3.25Mg-2.46Cu-0.16Fe | 46 | 0.5 | 750 | 1 |
Al-5Ti-1B-0.1Er [ | Al-10Zn-1.9Mg-1.6Cu-0.12Zr | 40 | - | - | 1 |
Categories | Advantages | Disadvantages | Scope of application |
---|---|---|---|
ECAP | Low requirement of material ductility, simple technology | Unsuitable for continuous production, fast consumed die | Poor plastic materials |
HPT | Uniform deformation, low deformation resistance, low porosity, no introduction of contamination | Limited shape and size of product, unsuitable for continuous production, complex process parameters | Small size disk sample |
ARB | Low cost, no requirement of special equipment | Edge cracking, high device damage | Suitable for large-scale industrial production and new composite materials |
CEC | Suitable for large-volume specimen, defects of initial microstructure can be eliminated, wide range of processing temperature | Limited extrusion ratio, limited specimen size, unsuitable for continuous production | Suitable for hard deformed metal and industrial production. |
FSW | Low distortion of workpiece, good dimensional stability and repeatability, no loss of alloying elements, excellent properties in the joint area, fine microstructure, energy conservation | Residual pinhole in the joint part, low welding speed, limited shape of the joint | Suitable for all series of aluminum alloys and metals with high welding crack susceptibility |
Table 9 Different SPD methods
Categories | Advantages | Disadvantages | Scope of application |
---|---|---|---|
ECAP | Low requirement of material ductility, simple technology | Unsuitable for continuous production, fast consumed die | Poor plastic materials |
HPT | Uniform deformation, low deformation resistance, low porosity, no introduction of contamination | Limited shape and size of product, unsuitable for continuous production, complex process parameters | Small size disk sample |
ARB | Low cost, no requirement of special equipment | Edge cracking, high device damage | Suitable for large-scale industrial production and new composite materials |
CEC | Suitable for large-volume specimen, defects of initial microstructure can be eliminated, wide range of processing temperature | Limited extrusion ratio, limited specimen size, unsuitable for continuous production | Suitable for hard deformed metal and industrial production. |
FSW | Low distortion of workpiece, good dimensional stability and repeatability, no loss of alloying elements, excellent properties in the joint area, fine microstructure, energy conservation | Residual pinhole in the joint part, low welding speed, limited shape of the joint | Suitable for all series of aluminum alloys and metals with high welding crack susceptibility |
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