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CHAPTER 3

Severe Plastic Deformation


Methods for Sheets
3.1 INTRODUCTION
This chapter aims to clarify the functional and structural principles of
ultrafine grained and nanostructured sheet production processes devel-
oped over the past two decades. As mentioned in the previous chapters,
severe plastic deformation (SPD) methods are used to produce bulk mate-
rial, sheets, and tubes. In this chapter, we will only refer to the methods
that are suitable for sheet forming. Furthermore, we will consider the fea-
tures of each procedure in detail. The techniques introduced in this chap-
ter are all top-down approaches in which materials with ultrafine or
nanostructured grains are produced from coarse-grained materials by
severe plastic deformation. Table 3.1 shows a list of SPD methods pre-
sented in the last few years.
The functional structures of each of the above methods are discussed
in detail in this chapter to specify the development of severe plastic defor-
mation. In each of the presented methods, various aspects of the defor-
mation behavior are considered, so as to compare and determine the
efficiency of each method.

3.2 ACCUMULATIVE ROLL-BONDING (ARB)


Accumulative roll-bonding (ARB) was developed in 1998 by Saito et al.
and it is based on conventional rolling as one of the most useful metal
forming methods [1]. The principle of ARB is illustrated in Fig. 3.1. In
the ARB process, conventional roll bonding after stacking of the two
strips is done repeatedly. The interfaces are first degreased and wire-
brushed to enhance the bond strength. In the ARB process, for 50%
rolled sheet, the rolled metal length is cut into two halves, which are
again surface-treated, stacked, and roll-bonded. To obtain a unit of solid
metal sheet, the rolling process is not only a deformation process but also
a bonding process.

Severe Plastic Deformation © 2018 Elsevier Inc.


DOI: https://doi.org/10.1016/B978-0-12-813518-1.00003-5 All rights reserved. 113
114 Severe Plastic Deformation

Table 3.1 Various SPD methods suitable for deforming sheet samples
Process Inventors Year

Accumulative roll-bonding (ARB) Saito et al. [1] 1999


Conecone method (CCM) Bouaziz et al. [2] 2007
Constrained groove pressing (CGP) Shin et al. [3] 2002
Rubber pad-constrained groove pressing (RP-CGP) Borhani et al. [4] 2012
Constrained groove rolling (CGR) Lee et al. [5] 2002
Friction stir processing (FSP) Mishra et al. [6] 1999
Equal channel angular rolling (ECAR) Lee et al. [7] 2001
Repetitive corrugation and straightening Haung et al. [8] 2001
Repetitive corrugation and straightening by rolling Mirsepasi et al. [9] 2012
Asymmetric rolling Kim et al. [10] 2001
Continuous frictional angular extrusion (CFAE) Huang et al. [11] 2007
Continuous cyclic bending (CCB) Takayama et al. [12] 1999

Degreasing,
wire brushing

Surface treatment Cutting

Stacking

Roll bonding

Figure 3.1 Schematic representation of the accumulative roll-bonding (ARB) method.

The thickness of the sheet after n passes is [1]:


t0
t5 (3.1)
2n
where the thickness reduction per cycle is 50% and t0 is the initial thick-
ness. The total reduction, rtot , after n passes is [1]:
t 1
rtot 5 1 2 512 n (3.2)
t0 2
Severe Plastic Deformation Methods for Sheets 115

Therefore, the equivalent plastic strain ε calculated from von Mises


yield criterion is expressed by [1]:
  
2 1
ε 5 n pffiffiffi ln 5 0:8n (3.3)
3 2
where a plane strain condition in which no lateral spreading existence
was considered. The deformation process may be changed with different
lubrication conditions and surface brushing. Therefore, due to the
friction at the roll surfaces, a shear strain component is created in addition
to the rolling strain similar to conventional cold rolling [13,14]. The main
problem with the ARB process is that cracks can occur in the metal due
to free deformation at the free edges without enough hydrostatic
compressive stresses, and edge cracks may occur in the sheet, especially at
higher strains [15]. The ARB process requires a high-capacity rolling
machine to enhance a high-reduction ratio leading to good bonding
between sheets. In addition, performing the experiments at low tempera-
ture would result in insufficient ductility and bond strength [1,16,17],
while high temperatures facilitate grain coarsening and dynamic
recrystallization [1820].
To speed up the ARB method, accumulative roll bonding and
folding (ARBF) was developed by combining the advantages of ARB
and folding processes [21]. In the ARBF process, the multilayer
metal/composite is folded between two consecutive rolling passes
instead of cutting.

3.3 CONECONE METHOD (CCM)


Another suitable method for producing UFG and NS sheets, named
CCM, was first invented by Bouaziz et al. in 2007 [22]. CCM is based
on the use of a conical plunger and a conical die to deform a conical
sheet sample of a given material by applying a force F and a torque C on
the tool (Fig. 3.2). The force is used to impose hydrostatic pressure, and
the torque to deform the ring by shear. In many aspects, this process is
perceived to have been developed based on the high-pressure torsion
(HPT) method. If sticking between the workpiece and the tooling can be
established, very large plastic shear strains and concomitant grain refine-
ment can be achieved. The deformed workpiece can be cut and rolled to
obtain a flat product [22].
116 Severe Plastic Deformation

Die

F R
x ϕ

Plunger

Sample

Figure 3.2 Schematic view of a CCM design.

The effective strain in the geometry of the CCM process is as follows


[22]:
2πN:RðxÞ
ε5 pffiffiffi (3.4)
3:t
where t is the thickness of the sample, N is the number of turns, and
RðxÞ is the radius at a point on the axis from the apex. The strain
decreases linearly with distance along the central axis and toward the apex
of the cone. In the CCM process, shear strain is applied by friction forces
acting on large surfaces under a high hydrostatic stress in the deformation
zone. An inhomogeneous microstructure along the axial and radial direc-
tions has been reported. Moreover, low hydrostatic compressive stress is
observed at the free edge with unconstrained plastic flow [20]. This allows
slipping between the die/the punch and the sample in the free region and
leads to a reduction in strain at the region close to the sample edge [23].
The main benefits of CCM over the HPT technique are that much larger
workpieces can be produced and can be turned into sheet products of
sizeable dimensions [22].

3.4 CONSTRAINED GROOVE PRESSING (CGP)


Constrained groove pressing (CGP) is an intense plastic straining tech-
nique for the fabrication of plate and sheet samples with UFG structures
without changing their initial dimensions. The CGP process is shown
Severe Plastic Deformation Methods for Sheets 117

Figure 3.3 A schematic drawing of the different stages of the CGP process.

schematically in Fig. 3.3 [3]. In this process, the sample is placed between
a set of asymmetrically upper and lower corrugated dies constrained by a
hollow cylinder. As pressing is performed, the inclined region (hatched
area in Fig. 3.3b) is subjected to pure shear deformation under plane
strain conditions, whereas no deformation is applied at the flat region
(unhatched area). A pressing leads to a shear strain of 1 (effective strain,
εeff 5 0.58) at the deformed zone when the groove angle (θ) is designed
as 45˚. Then, the sample is pressed with a set of flat dies as shown in
Fig. 3.3c. Flat pressing applies a reverse shear deformation to the
deformed region, while the previous undeformed region remains
unchanged. The accumulative equivalent strain of the deformed zone col-
ored in Fig. 3.3c will be doubled and reaches 1.16. The specimen is then
rotated by 180˚ (Fig. 3.3d). This causes the undeformed zone to be
strained by further pressings because of the asymmetry of the grooved
dies. Therefore, the consequent pressings with grooved and flat dies yield
a homogeneous and uniform equivalent strain of 1.16 throughout the
sample. A large amount of equivalent plastic strains can be applied to the
sample without changing its initial dimensions. Thus, an ultrafine grained
structure can be obtained by repeated processing by CGP [3].
Referring to Fig. 3.4 and Eqs. (3.5)(3.9), it can be seen that the
effective strain in a single pressing is equal to 0.58 [24].
t
γ xy 5 γ 5 tanθ 5 5 1 (3.5)
t
118 Severe Plastic Deformation

t
θ
t

Figure 3.4 The deformed region in the groove pressed sample.

rffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
iffi
2 h 2  2 i 4h
εeff 5 εx -εy 1 εy -εz 1 ðεz -εx Þ 1 εxy 1 εyz 1 εzx (3.6) 2 2 2 2
9 3

γxy γ
εxy 5 5 (3.7)
2 2

εx 5 εy 5 εz 5 εyz 5 εxz 5 0 (3.8)

sffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
 2
4 γ=2 γ
ð3:6Þ; ð3:7Þ; ð3:8Þ.εeff 5 5 pffiffiffi .Uεeff 5 0:58 (3.9)
3 3
The plastic strain distributions at the end of one pass show an inho-
mogeneous distribution. The strain at the central region of the sheet
thickness is greater than that of the surface [25] due to the influence of
friction. Controlling the die parameters needs to be designed carefully. At
the larger groove angles, pressing at high cycles of CGP leads to the for-
mation of cracks at the corner of the groove, resulting in a severe stress
concentration on the metal [26]. The CGP method can be regarded as a
discontinuous and time-consuming process [27].
In CGP, the sheet specimen is tightly constrained between the lower
and upper dies. Thus, when the dies press the sheet, the sheet can move
neither in the longitudinal direction nor in the transverse direction.
When processing via unconstrained groove pressing or simply groove
pressing (GP), there is no constraint, and the sample moves freely along
the longitudinal and transverse directions as shown in Fig. 3.5 [26,28].
However, the CGP method exhibits several limitations that make this
process unsuitable for industrial applications. It is difficult to apply very
Severe Plastic Deformation Methods for Sheets 119

Normal Top die


direction (ND)

Longitudinal
Sample
Transverse
direction (TD) direction (LD)

Bottom die

Figure 3.5 Schematic of the groove pressing (GP) technique.

high strains because of relatively free forming of the sample during the
CGP processing. The sample surface is free, and the hydrostatic compres-
sive stress is relatively low [29]. This increases the possibility of the forma-
tion of cracks at higher strains [30]. Besides, it is hard to process large
samples using this process.

3.4.1 Semiconstrained Groove Pressing (SCGP)


To simplify performing of the CGP process, another type of groove press-
ing entitled semiconstrained groove pressing (SCGP) has been developed
[24,31]. In the SCGP process, the sheet specimen is placed between the
dies that are firmly constrained by the channel instead of a hollow con-
tainer used in the CGP. As a result, the sheet specimen is constrained
between the die outer walls and the sample cannot move in the longitudi-
nal direction [26].

3.4.2 Rubber Pad-Constrained Groove Pressing (RP-CGP)


To simplify the die, another type of CGP process named rubber pad-
constrained groove pressing (RP-CGP) has been developed [4]. Unlike
CGP, which uses a pair of grooved and flat dies, one grooved and one flat
die are used in the RP-CGP process. Both the upper grooved and flat
dies are replaced by a flexible rubber pad under a punch as illustrated in
Fig. 3.6. The rubber pad acts as both a grooved die for the corrugating
stages and a flat die for flattening [26]. This flexible rubber pad increases
the hydrostatic pressure and greatly improves the workability of the sheet
[32], increasing the maximum number of CGP passes before metal
cracking.
120 Severe Plastic Deformation

Figure 3.6 A schematic drawing of the RP-CGP process.

3.4.3 Constrained Groove Rolling (CGR)


To make the CGP method suitable for deforming long sheets, CGR has
been developed in which the lower and upper rolls are as shown in
Fig. 3.7. A plate-shaped workpiece is repeatedly corrugated and flattened
between the rolls. In groove passes, as the asymmetrically grooved parts of
the rolls press the workpiece, the inclined regions of the workpiece are
subjected to shear deformation, while the flat regions remain unchanged.
In flattening passes performed by the flat parts of the rolls, the deformed
regions are subjected to reverse shear deformation while the undeformed
regions remain unchanged. The workpiece is then rotated by 180˚, allow-
ing the undeformed regions to be deformed by the rolls, and the groov-
ing and flattening procedure is repeated. The CGR process seems more
practical than the CGP process since the material can be continuously
fabricated [33].

3.5 FRICTION STIR PROCESSING (FSP)


Friction stir welding (FSW) is a solid-state welding process with a simple
concept that has proven to be a useful method for joining materials with
poor fusion weldability, such as dissimilar and hard-to-weld materials
[3436]. Friction stir processing (FSP), developed by Mishra et al.
[37,38], is an effective tool for microstructural modification and produc-
ing UFG metals based on FSW [39,40]. As shown in Fig. 3.8, FSW is a
remarkably simple process in which an almost solid and rigid rotating tool
with a specially designed pin and shoulder presses into the sheets or plates
and is then moved along the sample. The two primary functions of the
Severe Plastic Deformation Methods for Sheets 121

Figure 3.7 Photograph showing the CGR apparatus [33].

Downward force

n
io
Tool rotation ct
dire
Shoulder
ing
Friction stir e ld
W
welded region

Pin

1st SPDed sheet 2nd SPDed sheet

Figure 3.8 Schematic of FSW/FSP.

tool are heating of the workpiece as a result of friction between the


shoulder and sample surface, and stirring the material by severe local plas-
tic deformation. The deformation of the material around the tool pin can
be quite complex because of the geometrical features of the tool [41].
During the FSP process, the material experiences severe plastic deforma-
tion at an elevated temperature. This results in the formation of fine or
ultrafine grained equiaxed recrystallized microstructures [4244]. There
are many process parameters, such as rotational tool speed, traverse speed,
tilt angle, and tool offsetting that influence the properties of the joints.

3.6 EQUAL CHANNEL ANGULAR ROLLING (ECAR)


The ECAR process is illustrated in Fig. 3.9. As shown in the figure, the
process consists of two dies at the outlet and two rolls at the inlet. The
122 Severe Plastic Deformation

Guide roll

Upper die

0.85 t0
t0

Feeding roll
t0
Lower die

Figure 3.9 A schematic illustration of the ECAR process.

thicknesses of the inlet and outlet channels are almost the same, while at
the deformation zone between rolls the thickness is decreased to
B0.850.95 t0 from t0. However, the sheet thickness at the outlet is
equal to the initial thickness. The diameter of the feeding and guide rolls,
their rotational speed, the frictional behavior of rolls and dies, the sheet
properties, and thickness variation are the main effective parameters of
this process. The ECAR process is a counterpart to the ECAP method,
which is suitable for processing sheets or long rods.

3.7 REPETITIVE CORRUGATION AND STRAIGHTENING (RCS)


The RCS process consists of two steps: corrugation followed by straight-
ening. This process has two variations: discontinuous (Fig. 3.10A) and
continuous (Fig. 3.10B). It is clear that the RCS process in the continu-
ous state can be easily adapted to a rolling mill which is suitable for indus-
trial production of UFG and NG metals. By pressing the corrugated
workpiece between two flat plates, the corrugated sample is straightened.
However, this stage can be done using flat cylindrical rolls in a continuous
variant of RCS [8]. At first glance, the RCS method seems to be very
simple and effective. Precise inspection may show that the hydrostatic
pressure is relatively low as a result of free deformation at the edges,
which facilitates the formation of micro- and nanocracks during the pro-
cess. This limits the capability of the process for applying very large strains
and consequently increasing the minimum saturated grain size.
Severe Plastic Deformation Methods for Sheets 123

Figure 3.10 (A) Schematic of the discontinuous and (B) continuous RCS process for
SPD processing of sheet materials [8].

3.8 REPETITIVE CORRUGATION AND


STRAIGHTENING BY ROLLING (RCSR)
RCSR is an SPD technique suitable for deforming sheets by accumulative
strain in the material utilizing special corrugated rolls. This method is
fairly similar to constrained groove rolling. Fig. 3.11 depicts a schematic
of the RCSR method. In a design presented by the inventors from the
University of Tehran, the width and diameter of the rolls are 200 mm and
110 mm, respectively [9]. At the first step of the RCSR process, as shown
in Fig. 3.11B, a sheet specimen is rolled between a pair of asymmetrically
corrugated rolls in which some regions of the workpiece are subjected to
the deformation. The workpiece experiences this step for five cycles. The
corrugated workpiece is then rolled between a pair of flat rolls as shown
in Fig. 3.11. The second step is repeated for up to seven cycles to make
the sheet relatively flat. At this point, half of the RCSR cycle is com-
pleted, and the workpiece is rotated 180˚, and the previous steps are
repeated so that the sample experiences one pass RCSR. This results in
the distribution of plastic strain throughout the workpiece. The repetition
of the following passes appears to produce uniform deformation in the
sample. The gap between rolls can be adjusted so that the sheet is sub-
jected to additional plastic strain during feeding which leads to decreasing
the thickness of the sample. As a result, the workpiece is expected to be
wider, thinner, and longer than its initial size. The inventors designed and
built this process on a laboratory scale, however, it can be easily adapted
for industrial-scale production. The RCSR process has several advantages,
including simplicity, continuity, and suitability for industrial-scale produc-
tion. The major drawbacks of the RCSR process are almost nonhomoge-
neous structure relative to the dimensional changes, and the possibility of
formation of micro- and nanocracks due to lower hydrostatic stresses.
124 Severe Plastic Deformation

Figure 3.11 Schematic illustration of the RCSR process [9].

The equivalent plastic strain at each pass can be calculated from the fol-
lowing equation [9]:
t0
ε 5 lnð1 1 Þ (3.10)
2R

3.9 ASYMMETRIC ROLLING


The differential speed rolling or asymmetric rolling process, shown in
Fig. 3.12, is very similar to the SPD method for processing sheet samples.
In contrast to conventional rolling, the rolls have a different velocity or
diameters leading to applying additional shear deformation into the metal.
The shear deformation may refine the microstructure to a greater extent
than conventional rolling.

3.10 CONTINUOUS FRICTIONAL ANGULAR


EXTRUSION (CFAE)
The CFAE technique, a method similar to ECAR, is illustrated in
Fig. 3.13. This method offers a solution to some problems of the ECAR
method and contains an ECAE-based die assembly part combined with
several innovative stages. In this approach, using a large frictional diameter
driving roll applies a normal pressure to the sample without any plastic
compression. Therefore, it is possible to carry out the continuous proces-
sing mainly by shear plastic deformation, which changes the dimension of
Severe Plastic Deformation Methods for Sheets 125

V1>V2

V1

V2

Figure 3.12 Schematic illustration of an asymmetric or differential speed rolling


process.

Figure 3.13 Schematic of the CFAE method: 1—driving roll, 2—sheet workpiece, 3—
workpiece support block, 4—die assembly, 5 and 6—first and second extrusion
channels, respectively [11].

the sample. The process may be repeated to apply ultrahigh plastic strains.
The CFAE technique offers several advantages, including being
suitable for processing industrial quantities of metals (mainly sheets, but
also bars and rods), and less extrusion force due to minimized die friction.

3.11 CONTINUOUS CYCLIC BENDING (CCB)


Fig. 3.14 shows a schematic of the continuous cyclic bending (CCB)
method [12]. As shown in the figure, bending and unbending procedures
126 Severe Plastic Deformation

offset Roll2 Roll4 t

Offset

Roll1 Roll3 Roll5

Figure 3.14 Schematic representation of a CCB machine [12].

are applied to the sample repeatedly. The strain value per pass is relatively
low (B0.1), and many passes are required to apply larger strain similar to
that of the SPD methods. The simplicity of the procedure is its main
advantage. However, several disadvantages exist in this method. Low
strain per pass, very low hydrostatic compressive stresses, and very low
shear strain may be considered critical challenges. It is therefore hard to
achieve UFG structures and achieve high-strength metals with this
method [45,46].

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