Shunjie Yao

In this study, the through-thickness texture of an accumulative roll-bonding (ARB)-processed aluminum single crystal was characterized using the Electron Backscatter Diffraction (EBSD) technique, and the texture reversal during ARB was investigated. Partitioned crystal rotation about the transverse direction (TD) and the activation of two sets of slip systems that resulted in TD-rotation and slip traces were evidenced. Reduced TD-rotation in certain layers of 2-ARB and 3-ARB corresponded to the destruction of previously formed slip traces, which resulted from the activation of the other set of slip systems. The partial texture reversal in ARB was experimentally revealed for the first time, and the revealing of texture evolution mechanisms helps with texture tailoring for better formability of ARB-processed sheet metals.

In this study, aluminum single crystals with a {1 0 0} (Cube) orientation were rolled under two conditions: with external constraints imposed by an external aluminum frame (3DRC) and without external constraints (3DR). The crystal plasticity finite element method (CPFEM) was used to simulate texture evolution, and the results corresponded well with experimental observations. The minor discrepancies observed were primarily attributed to the idealized conditions in the simulation. The results demonstrate that in the 3DR model, crystal orientations predominantly rotate around the transverse direction (TD), with non-TD rotations playing a secondary role. In contrast, the 3DRC model exhibits similar rotation patterns to 3DR at lower reductions, but at higher reductions, non-TD rotations become comparable to TD rotations. This difference results in more concentrated orientations in 3DR and more dispersed orientations in 3DRC. Additionally, analysis reveals that external constraints cause deformation behavior to deviate from the plane strain condition rather than move closer to it. The presence of external constraints alters stress and strain states, modifying the activation of slip systems and crystal rotations, leading to significant variations in slip activity, shear strain, and crystal rotation along TD.

Aluminum alloy, due to its low melting point and high thermal conductivity, deforms and contracts significantly during welding. To mitigate this and achieve full penetration in a single pass, this study uses GTAW (Gas Tungsten Arc Welding) additive manufacturing and optimizes welding groove parameters via the Box-Behnken Response Surface Methodology. The focus is on improving tensile strength and penetration depth by analyzing the effects of groove angle, root face width, and root gap. The results show that groove angle most significantly affects tensile strength and penetration depth. Hardness profiles exhibit a W-shape, with base material hardness decreasing and weld zone hardness increasing as groove angle rises. Root face width reduces hardness fluctuation in the weld zone, and an appropriate root gap compensates for thermal expansion, enhancing joint performance. The interaction between root face width and root gap most impacts tensile strength, while groove angle and root face width interaction most affects penetration depth. The optimal welding parameters for 7xxx aluminum alloy GTAW are a groove angle of 70.8°, root face width of 1.38 mm, and root gap of 0 mm. This results in a tensile strength of 297.95 MPa and penetration depth of 5 mm, a 90.38% increase in tensile strength compared to the RSM experimental worst group. Microstructural analysis reveals the presence of β-Mg₂Si and η-MgZn₂ strengthening phases, which contribute to the material’s enhanced mechanical properties. Fracture surface examination exhibits characteristic ductile fracture features, including dimples and shear lips, confirming the material’s high ductility. The coexistence of these strengthening phases and ductile fracture behavior indicates excellent overall mechanical performance, balancing strength and plasticity.

Texture evolution during accumulative roll-bonding (ARB) is complicated because of the change in the through-thickness position that results from repeated cutting–stacking and roll-bonding. In this study, a macro–micro two-scale modeling was carried out to investigate the behaviors of texture evolution during ARB. The finite element method (FEM) was used to predict the strain history at a macro-scale, while a crystal plasticity FEM was used to reproduce the texture at a micro-scale. The texture evolution along three different cutting–stacking paths was traced and investigated. The patterns of texture transition between the rolling-type, shear-type, and random-type textures were studied by using area fractions of texture components, the distribution of textures, and the distribution of crystal rotation angles.