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Investigation of internal cracks in aluminium alloy AA7075 forging

Article  in  Engineering Failure Analysis · January 2006

DOI: 10.1016/j.engfailanal.2005.01.006

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 Engineering Failure Analysis 13 (2006) 1–8
www.elsevier.com/locate/engfailanal

Investigation of internal cracks in aluminium alloy

AA7075 forging
R.K. Gupta *, P. Ramkumar, B.R. Ghosh
Mechanical Engineering Entity, Vikram Sarabhai Space Centre, Trivandrum 695022, India

Received 7 January 2005; accepted 8 January 2005

Available online 13 April 2005

Abstract

AA7075 aluminium alloy is a high strength age hard enable alloy. Although this alloy is not weldable, critical com-
ponents fabricated out of this alloy have aerospace applications in the form of forgings in T7352 temper condition. In
the case under investigation extruded billet was used as input material, and during ultrasonic testing of the forgings,
distinct discontinuities were observed. An exhaustive metallographic investigation was taken up in tandem with pro-
gressive machining to physically observe the cracks. Morphology and locations of cracks along with the attributable
factors were discussed and the remedial measures were suggested.

2005 Published by Elsevier Ltd.

Keywords: AA7075; Ultrasonic discontinuity; Microcracks; Coring

1. Introduction

Al alloy AA7075 is one of the most frequently used Al–Zn–Mg family of alloys due to its high strength
and superior resistance to stress corrosion cracking (SCC) in T7352 temper condition. For realisation of a
particular component, DC cast billet of diameter 380 mm was extruded to 290 mm diameter, and 440 mm
height of a block was used as an input material for the forgings. Forge stock material was processed
through a series of forging operations to the pre-machined required dimensions. Ultrasonic testing of
the forged block revealed the presence of unacceptable internal discontinuity in the middle of the block
(Fig. 1). To analyse the nature of discontinuity and its origin, a thorough investigation was carried out. This
paper presents the details of the investigation conducted for the above purpose. Various metallurgical

*
Corresponding author.
E-mail addresses: guptarohitg@rediffmail.com, rohitkumar_gupta@vssc.org (R.K. Gupta).

1350-6307/$ - see front matter
2005 Published by Elsevier Ltd.

doi:10.1016/j.engfailanal.2005.01.006
2 R.K. Gupta et al. / Engineering Failure Analysis 13 (2006) 1–8

Fig. 1. Ultrasonic defect location in the billet.

phenomena operative during processing were also carefully analysed and attempts were made to correlate
the process parameters with the microstructures to pinpoint the probable reasons of generation of such
cracks and suggest the remedial measures.

2. Processing history of forgings

DC cast billets homogenized at 470 C for 30 h. were ultrasonically qualified as per class B of AMS
2630A. Subsequently, the billets were hot extruded to diameter 290 mm. Extruded billets were subsequently
qualified as per class A. These extruded billets were preheated to the temperature of 440 C for 6 h. (prior to
forging) and intermittent reheatings were also carried out with the same cycle during forging operation.
Preheated billets were forged to the required size, along with required number of intermittent reheatings.
Finishing temperature of forging was maintained at 360 C throughout. A total reduction ratio of 12.8
was given to further improve the ultrasonic quality of the forgings and to meet the mechanical properties
and microstructural requirements in T7352 heat treated condition. The forgings were adequately machined
to 465 mm diameter · 170 mm before imparting T7352 heat treatment and final proof machining. As an
intermediate quality check, the forgings were subjected to ultrasonic inspection to ascertain the soundness
of the materials in the as-Forged condition. Ultrasonic signatures clearly revealed presence of discrete dis-
continuities in the centre region of the forging, resulting in rejection of the forgings. The location of a typ-
ical defect in a representative forging is schematically shown in Fig. 1.

3. Experimental

Samples from the locations around defective areas were identified for metallographic investigations to
understand the general microstructural features around the defects and to validate the ultrasonic test results
by physically revealing the defects. Optical metallography was carried out in all the directions. Two sample
pieces were cut from a representative forging and demarcated as 1 and 2 as shown in Fig. 2. Notation of
specimen for metallography observation from sample piece 1 and 2 is shown in Fig. 3.

Fig. 2. Sample pieces selected for metallography.

 R.K. Gupta et al. / Engineering Failure Analysis 13 (2006) 1–8 3

Fig. 3. Notation of metallography specimen from the sample pieces.

Four specimens were selected from sample piece 1, as per Fig. 3(a) and two specimens from the sample
piece 2 as per Fig. 3(b), to understand the flow pattern of grains and to physically detect the presence of
discontinuities/defects. Specimens were conventionally prepared by conventional polishing and etched with
KellerÕs reagent. All the areas of the selected samples were investigated using Olumpus make light micro-
scope. Photomicrographs for specimens from sample piece 1 are presented in Fig. 4.
In the case of sample piece 1 (Fig. 3(a)) visual defect was not observed. Samples from the ultrasonic de-
fect region were taken (sample piece 2) and subjected to ultrasonic test again to confirm the discontinuities.
Ultrasonic test of sample confirms the presence of defect. The sample was carefully milled to the anticipated
depth till the cracks were physically observed on the milled surface. Orientation of cracks is presented in
Fig. 5. It is perpendicular to the working direction of the forged billet.

Fig. 4. Photomicrographs of forged billet of the locations, described in Fig. 3(a).

4 R.K. Gupta et al. / Engineering Failure Analysis 13 (2006) 1–8

Fig. 5. Visual observation of crack.

Fig. 6. Full length crack along the cross-section plane of forged billet, 20·.
 R.K. Gupta et al. / Engineering Failure Analysis 13 (2006) 1–8 5

Fig. 7. Crack morphology in middle-side of the forging (2ML of the Fig. 3(b)).

Fig. 8. Presence of voids in the forging.

6 R.K. Gupta et al. / Engineering Failure Analysis 13 (2006) 1–8

Visually observed cracks on the milled surface of sample piece 2, was subjected to polishing to examine
the morphology of crack. Polished phase were etched with KellerÕs reagent and observed under optical
microscope. Full length crack was recorded and presented in Fig. 6. Crack morphology observation is
presented in Fig. 7. During the microstructural observation, voids are also noticed, as presented in
Fig. 8.

4. Results and discussion

It is a common observation that cast and homogenized billet subjected to mechanical working, such as
forging, rolling, extrusion, etc. results in uniform metallurgical structure. It means, ultrasonic quality will be
at least similar to cast billet quality if not better, due to mechanical working, which refines the structure.
But in the case under study, detection of ultrasonic discontinuity in the final stage (which were absent in
the earlier stage) indicates that quality of final product has not been improved.
Optical microstructure shows equiaxed recrystallized grains on the top of the forging (location 1TT of
Fig. 3(a)) with the grain size in the range of 100–250 lm (Fig. 4(a)). Length direction of forging near the top
(location 1TL of Fig. 3(a)) also shows similar equiaxed grains (Fig. 4(b)), since it is the area where effective
working is involved, it is expected to have equiaxed grains. But middle of the forging reveals metallurgical
structural difference from the top. Location Ô1MLÕ of Fig. 3(a), which is complementary location Ô1TLÕ of
Fig. 3(a), shows elongated grains (Fig. 4(c)). It also indicates the lack of sufficient working by presence of
elongated coring [1]. Middle cross-section of forged billet (location Ô1MTÕ of Fig. 3(a)) which is complemen-
tary to location Ô1TTÕ of Fig. 3(a), shows thicker cell boundary along with branching (Fig. 4(d)), which is
similar to cast cells [1]. Presence of undissolved compound particles similar to Al–Cr–Mn precipitate phase
[1] were observed in the microstructure. No microcracks have been noticed in sample piece 1 (i.e., sample
above of the defective area).
Physical observation of the cracks in the sample piece 2 (Fig. 5) and its subsequent microstructural
observation (Figs. 6 and 7) reveal the discontinuous microcracks. These cracks were not interconnected.
It is found that these cracks are aligned in the direction of elongated grains presented in Fig. 4(c) and 7(a).
After the above observation and understanding of the process, a progressive model of the total process
with respect to grain orientation and crack morphology is suggested, which is given in Fig. 9. Amount of
total working (reduction ratio) imparted on the forging from the input raw material stage is calculated as
12.8 and found to be sufficient to break the cast structure. But it could not ensure the absence of
discontinuities.
Presence of cast cells on the cross-section and elongated coring on the centre of forging suggests the
insufficient homogenisation of the cast billet, which could not be eliminated/refined during subsequent
mechanical working. Voids observed (Fig. 8) in the material are microscopic interdendritic porosities
(MIP), a kind of localized shrinkage porosity, which are formed during solidification of the alloy [2].
These voids/porosities could have aligned and flattened in the extrusion direction during extrusion. Dur-
ing subsequent forging operations, it continued to change its direction by change in the direction of
working. Repeated change in flattening direction of these porosities increased its sizes rather than welding
it and finally it could have lead to microcrack. Morphology of microcrack (Figs. 5 and 6) reveals that it
has originated through porosity, which did not combine because voids did not coalesce and resulted in
multiple cracks. Coring and presence of undissolved particles are also attributable to creation of micro-
cracks. The presence of microcracks, as presented in Figs. 6 and 7 is clearly due to the combined effect of
the microstructural aberrations carried through from cast ingot and inadequate homogenisation and thus
presumably cause low forgeability of the material at the lower range of stipulated forging temperature
band.
 R.K. Gupta et al. / Engineering Failure Analysis 13 (2006) 1–8 7

Fig. 9. Progressive model for crack generation during processing from billet casting to forging.

5. Conclusions

 Presence of macroscopic and microscopic interdendritic and shrinkage porosities is detrimental during
forming operations and should be minimized by process control during casting stage.
 Presence of coring indicates insufficient homogenisation. So homogenisation aspect of the alloy at the
ingot stage is to be properly understood to get coring free cast structure, as an input material for sub-
sequent downstream processing like extrusion/forging.
 Mechanical working steps with respect to direction are in conformity of the practiced process. However,
manipulation of the direction of working and amount of working required in each step, have definitive
advantage for processing ultrasonically sound forgings of AA7075 Al alloy.

Acknowledgements

We are grateful to Head MCD and his team for timely support extended during metallographic inves-
tigations and to Dy. Director, MEE for his constant encouragements and valuable suggestions. Authors are
thankful to Director VSSC for his kind permission to publish this work.
8 R.K. Gupta et al. / Engineering Failure Analysis 13 (2006) 1–8

References

[1] Al and Al alloys specialty handbook. Materials Park, OH: ASM International; 1994. p. 502–505.
[2] Marquis FDS. Microstructural evolution of porosity during casting and thermomechanical processing of aluminium based alloys.
In: Proceedings from materials solutions conference. Indianapolis, IN: ASM International; 2001. p. 173–181.

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