One-step fabrication of double-sided gradient-structured sheets by plastic flow machining with arrayed arc-sawteeth

Abstract

To address the problem of low efficiency in the machining of double-sided gradient-structured (GS) metallic sheets, a novel severe plastic deformation (SPD) technology, plastic flow machining with arrayed arc-sawtooth (PFM-AA), is proposed in this study. The PFM-AA process achieves significant grain refinement and forms a double-sided GS through single-step processing, as opposed to those that require multiple passes, such as surface mechanical attrition treatment (SMAT). Compared with conventional plastic flow machining (PFM) methods, the minimal deformation experienced by the core region preserves the coarse-grained structure and maintains excellent plasticity. Furthermore, by adjusting the arc-sawtooth parameters (arc angle and tooth pitch), the coarse-grained layer ratio can be regulated to achieve gradient controllability and a strength-ductility trade-off. In this study, the formation mechanism, microstructure, grain refinement mechanism, and mechanical properties of double-sided GS aluminum alloy AA1060 sheets with different arc angles and tooth pitches were investigated using experimental and simulation techniques. The results indicated that the established coupled Eulerian-Lagrangian finite element model based on a dislocation density-based model accurately reflected the evolution trends of the microstructure and mechanical properties. According to the electron backscatter diffraction (EBSD) results, both sides of the sheet were refined. The formed sheet showed a clear double-sided GS in hardness and the ultimate tensile strength (UTS) of the sheet reached 125.9 MPa while maintaining reasonable ductility (elongation to fracture: 27.66%). Accordingly, the PFM-AA process demonstrates significant application potential, providing an efficient SPD method for producing double-sided GS sheets.

Keywords

Double-sided gradient-structured / Plastic flow machining with arrayed arc-sawtooth (PFM-AA) / Dislocation density-based model / Mechanical properties

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Funding

National Natural Science Foundation of China(52075187)

Natural Science Foundation of Guangdong Province(2514050002646)

RIGHTS & PERMISSIONS

Shanghai University and Periodicals Agency of Shanghai University and Springer-Verlag GmbH Germany, part of Springer Nature