
doi: 10.26021/1807
handle: 10092/100696
Inhomogeneous material properties such as corrosion resistance, strength and creep can be found in cast or formed metals which are heat treated. The spatial variation comes from the gradient in grain sizes, which is a problem for any industry which forms/bends high strength metals such as in petrochemical refinery. The aim of this masters project was to investigate the rate of grain growth in brass which has a gradient in grain sizes. This was following on from prior work by Dr Dan Lewis (assistant supervisor) who found not-normal grain growth in simulated gradient grain growth calculations. Grain size engineering is one of a few methods engineers use to strengthen metals. One way to control grain size is through controlled solidification. The higher the undercooling (temperature difference between the liquid metal and the temperature at which solidifications begins) the higher the nucleation rate of new grains and thus the smaller the solidified grain size. Another method is through cold work followed by a heat treatment. Cold work is when a metal is deformed below a material-specific temperature called the recrystallisation temperature. Cold work causes the generation and motion of defects called dislocations. A dislocation is a line defect in the lattice. These harden the metal by generating internal strain in the metal. This is known as strain hardening. Strain hardening makes the metal harder but less ductile. When given enough thermal energy, atoms are able to move around which allows point and line defects to combine and eliminate each other. This is recovery and recrystallisation. These processes restore the original material properties; however, the size of the grains in the material will be reduced. A smaller grain size strengthens the material and is known as the Hall-Petch relationship. If the metal is left in this elevated thermal state, then atoms are able to migrate from one grain to the next. This results in a kinetic process where large grains increase in size and small grains shrink and disappear. Overall, the mean grain size increases, and this is the process known as grain growth. Simulations of grain growth in 2D were performed by Dr Lewis. A higher rate of grain growth occurred in samples which had a higher spatial gradient in grain size. The present work set out to test if the same phenomenon occurred experimentally. The metal in this work was 70/30 brass, an alloy with 70 wt.% Cu and 30 wt.% Zn. It has high ductility, and is a classical metal for grain growth studies. The gradient in grain sizes was created in this project using tensile cold work. A sample with constantly changing cross section was deformed to a known total gage deformation. This was followed by a series of interrupted heat treatments to recrystallise then grow grains. The grain size was measured after each heat treatment using large-scale optical images, and image analysis software ImagePro 10 was used to identify the grain boundaries. Because the stored cold work was dependant on the location, recrystallisation was able to be tracked as it progressed down the sample. Then the grain growth was also measured in the same sample which had a gradient in grain sizes. The rates of both recrystallisation and grain growth agreed with literature values in each analysis area. However due to using interrupted heat treatments there was significant thermal lag which may have altered the detailed results. This work focuses on tracking recrystallisation and measuring the grain growth in a series of gradient samples at five different temperatures. It includes developing a new method for material testing which would suit high-throughput material design for industries such as the petrochemical and nuclear sector which require high levels of testing before a new alloy can be put into service.
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