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ScienceDirect Defence Technology 10 (2014) 40e46
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Dynamic globularization prediction during cogging process of large size TC11 titanium alloy billet with lamellar structure Hong-wu SONG, Shi-hong ZHANG*, Ming CHENG Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China Received 27 October 2013; revised 26 December 2013; accepted 15 January 2014 Available online 29 January 2014
Abstract The flow behavior and dynamic globularization of TC11 titanium alloy during subtransus deformation are investigated through hot compression tests. A constitutive model is established based on physical-based hardening model and phenomenological softening model. And based on the recrystallization mechanisms of globularization, the Avrami type kinetics model is established for prediction of globularization fraction and globularized grain size under large strain subtransus deformation of TC11 alloy. As the preliminary application of the previous results, the cogging process of large size TC11 alloy billet is simulated. Based on subroutine development of the DEFORM software, the coupled simulation of one fire cogging process is developed. It shows that the predicted results are in good agreement with the experimental results in forging load and microstructure characteristic, which validates the reliability of the developed FEM subroutine models. Copyright Ó 2014, China Ordnance Society. Production and hosting by Elsevier B.V. All rights reserved. Keywords: Titanium alloy; Lamellar structure; Dynamic globularization; Prediction
1. Introduction Titanium alloys, particularly dual-phase titanium alloys, have been widely used as advanced structural materials in aeronautic applications. Especially, the alloy with a nominal composition of Ti-6.5Al-1.5Zr-3.5Mo-0.3Si (named TC11 alloy), which has a composition similar to Russia alloy VT9, is a typical dual-phase alloy and has now been the most widely used titanium alloy in aerospace field in China to produce the compressor discs and blades. Due to the additions of beta isomorphous element Mo, neutral element Zr and beta eutectoid element Si into Tie6Al base, TC11 alloy has a higher strength, better creep resistance and more excellent
* Corresponding author. Tel.: þ86 24 83978266; fax: þ86 24 23891320. E-mail address:
[email protected] (S.H. ZHANG). Peer review under responsibility of China Ordnance Society.
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thermal stability, especially at elevated temperatures compared with conventional Tie6Ale4V alloy [1,2]. The lamellar microstructure associated with as-cast or betaprocessed dual-phase titanium alloys has been found to break up or globularize dynamically during deformation and statically during post deformation annealing in the alpha/beta phase field, which plays a key role in development of desired microstructure for final forming or service. Therefore, the globularization process has received considerable attention [3e7]. Many studies have been focused on dynamic globularization of two phase titanium alloys. In early works, Kaybyshev, et al. [8e10] qualitatively studied the evolution of plate like microstructure during superplastic deformation, with strain rate being in the order of 103 s1 in the two phase alpha/beta region of VT9 alloy. The dynamic globularization process was found to be governed by the alpha-beta transformation and the development of grain boundary sliding. Semiatin, et al. [5,11] observed that the dynamic globularization of Tie6Ale4V alloy with colony alpha structure occurred at strain rate of lower than 0.01 s1; and the strains of 0.75e1.0 and 2e2.5
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H.-w. SONG et al. / Defence Technology 10 (2014) 40e46
were required for ‘initiation’ and competition of dynamic globularization, respectively. Later study [4,12,13] indicated that the dependence of dynamic globularization kinetics on test temperature and initial microstructure appeared to be complex. Recently submicron grain structure was achieved by warm deformation of Tie6Ale4V alloy at low temperature (550 C) and low strain rate (0.001 s1) as a result of dynamic globularization [14]. It can be found that the former researches were focused on globularization behavior at low strain rate or warm temperature. However, most thermomechanical processing of dual-phase titanium alloys for ingot breakdown on hammer or hydraulic press in industry was carried out at high temperature and high strain rate (above 0.01 s1). Although the most recently research by Park, et al. [15] indicated that the superplasticity of Tie6Ale4V alloy with martensite microstructure can be enhanced by its dynamic globularization generated at high strain rate (0.1 s1), and the quantitative analysis of dynamic globularization kinetics is still unclear under such conditions for alloys with colony alpha structure. In spite of the referenced studies, the modeling and quantitative prediction of the dynamic globularization of two phase titanium alloy parts during forging are still lacking. Few works on dynamic globularization prediction of titanium alloys were all based on the artificial neutral network models [16,17]. And as for the TC11 alloy, few researches have been conducted on dynamic globularization kinetics [18], but the model established was only for low strains [19]. For better understanding of the microstructure control through dynamic globularization during cogging, the subtransus deformation behavior and dynamic globularization evolution were firstly studied and modeled. And then the microstructure evolution in cogging process of large size billet was simulated and predicted. 2. Materials and experimental methods TC11 alloy used in this investigation chemical has the following composition (wt. %): Al 6.17, Mo 3.41, Zr 1.77, Si 0.285, Fe 0.054, C 0.014, N 0.01, H 0.0006, O 0.100, and the rest being Ti. The measured b transus temperature is about 1020 C. The received F10 mm wrought bars are heated to 1040 C and held for 30 min followed by furnace cooling. The initial microstructure of the heat-treated material is shown in Fig. 1.
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The microstructure shows a typical lamellar structure characterized by several alpha colonies in prior coarse b grains and a thick grain boundary alpha layer. The a and b lamellae are parallel to each other in the alpha colonies. The average b grain size is around 400e500 mm, and the average thicknesses of the a and b lamellae in colonies are about 1.5 mm and 0.35 mm, respectively. Cylindrical compressive specimens with 8 mm in diameter and 12 mm in height are machined from the heat-treated bars. Isothermal compression test is conducted on a Gleeble 3500 thermal simulator in the temperature range of 890e995 C and the strain rate range of 0.01e10 s1. Graphite sheets are used as high temperature lubricant on both top and bottom sides of the specimens. Furthermore, the tantalum plates are used to avoid high temperature reaction and reduce heat transfer between the specimens and the anvils. During the tests, the specimens are heated to the given temperatures at a heating speed of 5 C/s, and held for 3 min to ensure a uniform distribution of temperature in the specimen. They are compressed to the given reduction and then fast cooled to room temperature. The deformation temperature is measured by thermocouples welded to the center region of the specimen surface. The load-stroke curves obtained from the compression tests are finally converted into true stress-true strain curves. The deformed specimens are sectioned parallel to the compression axis for microstructural analysis. The samples for optical metallographic examination are mechanically polished and etched with a solution consisting of 10 pct HF, 20 pct HNO3 and 60 pct H2O. Because of the inhomogeneous deformation and non-uniform strain distribution in the compressed specimens, FEM is applied to calculate the local strains for microstructure observation. Since the beta phase transforms during cooling, the primary alpha phase, which governs the structure type of alloy, is mainly studied. Globularization behavior of the alpha lamella is then quantified using moderate magnification optical photographs by a quantitative metallographic image analysis system considering alpha phase with the aspect (length/ width) ratio lower than 2 globularized phases. 3. Materials modeling 3.1. Flow behavior and constitutive model The stressestrain behaviors resulting from the uniaxial compression tests at the temperatures of 890 Ce995 C and
Fig. 1. SEM image of lamellar structure of TC11 alloy achieved by treating at 1040 C and holding for 30 min.
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Fig. 2. Stressestrain curves obtained via compression tests (the dot line is temperature corrected by deformation heating).
the strain rates of 0.01 s1e10 s1 are presented in Fig. 2. In all the flow curves, the flow stress increases first and then decreases with the increase in strain. It can be seen from Fig. 2 that a peak flow stress appears at relatively low strain (around 0.05), and the different levels of flow softening exist and the flow curves exhibit a trend of steady state flow at strain over 0.9. Furthermore, the overall degree of flow softening is found to be comparable under all the test conditions. According to the above flow behavior including quick hardening and moderate softening, the constitutive model is established by combination of the physical-based hardening model and a phenomenological softening model as follows: s ¼ swh ðswh ss ÞXsoft 12 2 2 swh ¼ s2 ss þ s0 sss expðbεÞ h n i Xsoft ¼ 1 exp k εεp
ð1Þ
The ideal saturated stress sss and steady state stress ss are found to be functions of temperature and strain rate which can be expressed as linear relationship with lnZ (ZenereHollomon parameter), as shown in Fig. 3: sss ¼ 1535:32 þ 35:91 ln Z
ð2Þ
ss ¼ 1226:46 þ 26:781 ln Z
ð3Þ
Z ¼ ε_ expð529000=RTÞ
ð4Þ
3.2. Dynamic globularization modeling The deformed microstructure is analyzed quantitatively to achieve the evolution of globularization fraction and the size of a phase with strain. The results show that the dynamic globularization kinetics is very sensitive to deformation
where swh is the flow stress during quick hardening, sss is the saturated stress without flow softening, ss is the steady state stress, and Xsoft is the flow softening fraction. The parameters s0, b, εp, k, n are all material constants, which values can be obtained through non-linear fitting method and are listed in Table 1. Table 1 Constant values of material. s0 (MPa)
b
εp
k
n
3.838
58.823
0.0581
0.219
0.834
Fig. 3. The linear relation plot between ss- lnZ and sss- lnZ.
H.-w. SONG et al. / Defence Technology 10 (2014) 40e46
temperature and strain rate, which can be related to the globularization mechanisms [20] . It can be seen from Fig. 4 that the globularization fraction of a phase fg has a linear relationship with strain in logelog pattern, indicating that the relation between globularization fraction and strain conforms to the Avarmi equation. And the size of globularized a phase D shows a liner relationship with lnZ (ZenereHolloman parameter), but the slope is highly depended on the strain rate, as shown in Fig. 5.
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Now a kinetic model of lamellar dynamic globularization is established, in which the fraction fg and size D of dynamic globularized a phase are expressed as functions of deformation temperature, strain rate and strain, respectively, in the following models n
fg ¼ 1 exp½ k$ðε εc Þ D¼
ð5Þ
31:63084 0:61249 ln Z ε_ ¼ 0:01s1 2:37124 0:0321 ln Z 0:1 ε_ 10
ð6Þ
where εc and n are materials constants dependent on strain rate shown in Table 2, and k is linear function of lnZ shown in Fig. 6. Table 2 εc and n values at different strain rates. Strain rate (s1)
εc
n
0.01 0.1e10
0.15 0.5
2.75 1.4
Fig. 6. Linear relation between k and lnZ under different deformation conditions.
Fig. 4. Linear relation between fg and ε at different deformation temperatures.
Fig. 5. Linear relation between D and lnZ at different strain rates.
4. Results and discussion In the cogging process, the size of the billet is F80 140 mm. The billet is heated to 1040 C and held for half an hour, and then air-cooled to room temperature. The original microstructure of the material is lamellar structure after b treatment, shown in Fig. 7. The grain size is about 300e400 mm, the thickness of grain boundary a lamella is about 3 mm, and the thickness of colony a lamella is about 2 mm. The original microstructure shows the features similar to the one used for compression test and materials modeling. The billet cogging process is shown in Fig. 8. The cogging load is experimentally recorded at certain time. Fig. 9 shows the variation of experimental and FE predicted cogging loads with time. Good agreement between the experimental and simulation results can be obviously seen from Fig. 9,
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H.W. SONG et al. / Defence Technology 10 (2014) 40e46
Fig. 7. Microstructure of TC11 alloy rod billet.
Fig. 8. Flowchart of one fire stage cogging process.
seen from Table 3 that the simulated results fit well with the experimental ones, indicating the feasibility of the proposed dynamic globularization kinetics model. Through further investigation, it can be found that both the fraction and size of globularized a phase obtained by simulation are all smaller than those obtained by experiments, and the strain path change during (cogging compared to uniaxial compression) can improve the dynamic globularization of titanium alloy, which
Fig. 9. Comparison of load-time data between simulated and experimental results.
indicating that the established constitutive model is applicable in complicated forging process for TC11 alloy. The simulated fraction of dynamic globularization at the central section is shown in Fig. 10. It can be seen that the globularization fraction is between 20% and 90% and significantly different at different positions, which can be more clearly seen from the simulated globularization evolutions at four typical positions (shown as 1e4), indicating non-uniform microstructure distribution. The microstructures at the positions corresponding to the four points shown in Fig. 10 in the cogging experiments are shown in Fig. 11. The comparison of globularization kinetics between simulation and experimental results is shown in Table 3. It can be
Fig. 10. Evolution of simulated lamellar globularization fraction at different positions.
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Fig. 11. Microstructures at different positions in the cogged billet as shown in Fig. 10(a).
References Table 3 Comparison of simulated and experimental globularization results. Position
1 2 3 4
Globularization fraction/%
Globular size/mm
Exp. predicted
Exp. predicted
100 90 82 25
89 80 65 20
4.4 4.0 1.6 1.2
3.0 2.5 0.89 0.8
is different from the results presented in Ref. [10]. The effect of strain path change on glolurization kinetics and the mechanism need to be further studied. 5. Conclusions A constitutive model and a dynamic globularization model are established for TC11 alloy with lamellar structure during subtransus deformation. FEM simulation based on the established models gives good prediction of load and microstructure evolution for TC11 alloy during subtransus cogging, and can be applied for simulation and optimization of cogging or other subtransus hot working processes of TC11 alloy with lamellar structure to realize microstructure control. And the strain path change during subtransus deformation is found to improve the globularized kinetics of a phase, which also needs to be further studied.
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