Strain-induced grain growth of cryomilled nanocrystalline Al in trimodal composites during forging

Grain growth of nanocrystalline aluminum (ncAl) in trimodal Al metal-matrix-composites (MMCs) during hot forging was investigated. The ncAl phase formed through cryomilling of inert gas-atomized powders in liquid nitrogen has an average grain size down to 21 nm, exhibits excellent thermal stability. However, substantial grain growth of ncAl up to 63 nm was observed when the Al MMCs were thermo-mechanically processed even at relatively low temperatures. Grain growth of the cryomilled ncAl phase in trimodal Al MMCs after hot forging was documented with respect to temperature ranging from 175 °C to 287 °C, true strain ranging from 0.4 to 1.35 and strain rate ranging from 0.1 to 0.5 s−1. Hollow cone dark field imaging technique was employed to provide statistically confident measurements of ncAl grain size that ranged from 21 to 63 nm. An increase in forging temperature and an increase in true strain were correlated with an increase in grain size of ncAl. Results were correlated to devise a phenomenological grain growth model for forging that takes strain, strain rate and temperature into consideration. Activation energy for the grain growth during thermo-mechanical hot-forging was determined to be 35 kJ/mol, approximately a quarter of activation energy for bulk diffusion of Al and a half of activation energy for static recrystallization.

► Grain growth of cryomilled nanocrystalline aluminum during hot forging. ► Use of hollow cone dark field imaging technique in TEM for grain size measurement. ► Grain growth model of strain, strain rate and temperature for forging optimization.