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 Chapter 14

Equal Channel Angular Extrusion Characteristics on

Mechanical Behavior of Aluminum Alloy
Abiodun Ayodeji Abioye, Ojo Sunday Isaac Fayomi,
AbimbolaAyodeji
Abiodun PatriciaAbioye,
Idowu Popoola
Ojo Sunday andIsaac Fayomi,
Oluwabunmi Pamilerin Abioye
Abimbola Patricia Idowu Popoola and
Oluwabunmi Pamilerin
Additional information Abioye
is available at the end of the chapter

Additional information is available at the end of the chapter

http://dx.doi.org/10.5772/intechopen.71019

Abstract
Materials strengthened by conventional methods such as strain hardening, solute addi-
tions, precipitation and grain size reinement are often adopted in industrial processes.
But there is limitation to the amount of deformation that these conventional methods can
impact to a material. This study focused on the review of major mechanical properties
of aluminum alloys in the presence of an ultraine grain size into polycrystalline materi-
als by subjecting the metal to an intense plastic straining through simple shear without
any corresponding change in the cross-sectional dimensions of the sample. The efect of
the heavy strain rate on the microstructure of aluminum alloys was in reinement of the
coarse grains into ultraine grain size by introducing a high density of dislocations and
subsequently re-arranging the dislocations to form an array of grain boundaries. Hence,
this investigation is aimed at gathering contributions on the inluence of equal channel
angular extrusion toward improving the mechanical properties of the aluminum alloys
through intense plastic strain.

Keywords: equal channel angular extrusion, strain hardening, severe plastic deformation

1. Introduction

1.1. Deformation processes

Solid materials transforms from one shape to another through a process called deformation.
Solid materials can be plastically deformed into complex shapes to obtain a material hav-
ing the desired geometry and properties required [1]. Deformation processes are commonly

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distribution, and reproduction in any medium, provided the original work is properly cited.
264 Aluminium Alloys – Recent Trends in Processing, Characterization, Mechanical behavior and Applications

used with other unit operations such as casting, machining, grinding and heat-treatment.
These unit operations occur during the transformation of raw materials to inished parts [2].
Deformation process generally can be classiied into two; (1) bulk forming process and (2)
sheet forming process. Rolling, extrusion and forging are examples of bulk forming process
while stretching, langing, drawing and contouring are sheet forming process. Input materi-
als for bulk forming processes are usually in form of billets, rods and slabs while the input in
sheet forming processes are usually in sheet blank form [2]. Deformation processes work by
stressing metal suiciently to cause plastic low into desired shape. The processes also alter
the grain sizes of the materials and induce plastic strains into the materials. Some deformation
processes used mostly are rolling, extrusion, forging, extrusion and wire drawing. Extrusion
process is considered for the purpose of this study.
Hall-Petch relation shows that the yield stress increases as reinement of grain size increases. It
implies that the mechanical behavior of a metal will not be the same if its grain size changes. In
order to improve properties of metal, methods of changing grain size is very important. There
has been reported limitation of conventional metallurgy processes (such as rolling, forging,
drawing and extrusion) in that they cannot supply metals whose grain sizes are substantially
smaller than engineering micro-components in dimension [3]. In conventional metal forming
operation the amount of plastic strain produced is often limited. Recently, materials with
grain structures in the nanoscale range are of high interest. Nanomaterials’ ability to decrease
the geometrical dimensions of diferent mechanical devices makes nano structural materials
atractive in engineering world. Successful shaping methods of engineering nanocomponents
are required for building nanodevices, this can be achieved through botom-up approach
method where the building blocks are in atomic and molecular levels [3, 4]. Merging the man-
ufacturing process of nanomaterials with material fabrication is highly challenging in terms
of cost of making many of the raw components for functional nanomaterials. Time required
for performing any engineering work at nano scale is also a considerable challenge. These
challenges often reduced mechanical response and electrical properties; likewise caused
spatial distortions, suboptimal thermal behavior, which weakens the general system perfor-
mance [3, 4]. Another way is to use top down approach where bulk materials are restructured
to nanoscale level using traditional shaping methods while constructing systems and devices
at the micro and nano scales.
Severe plastic deformation (SPD) process has been shown as one of the major ways of fabri-
cating bulk nanostructured samples and billets out of diferent metals and alloys [5]. The irst
developments and investigations of nanostructured materials processed using SPD methods
were fulilled by Valiev and his co-workers over than 10 years ago.

1.2. Severe plastic deformation (SPD)

Severe plastic deformation was deined as the intense plastic straining under high imposed
pressure [6, 7]. Severe plastic deformation methods are used to convert coarse grain met-
als and alloys into ultraine grained (UFG) materials [8, 9]. The ultra-ine grain materials
obtained possesses improved mechanical and physical properties which impart on them a
wide commercial use. Severe plastic deformation is a new metal forming process capable of
 Equal Channel Angular Extrusion Characteristics on Mechanical Behavior of Aluminum Alloy 265
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generating very large or severe plastic deformation in a material without a major change in
the billet geometry [5]. The method covers all metal forming processes which are based on
simple shear and/or repetitive reversed straining and tend to preserve the initial shape of the
billet. Diferent SPD processes are shown in Figure 1. Where ε is the strain; t is the torsion; n
is the number of passes; ϕ is half of the inner die angle; D is the initial diameter; d is the inal
diameter; H is the height; W is the width; T is the initial thickness; t is the inal thickness and
r is the radius.

1.3. Equal channel angular extrusion (ECAE) process

Equal channel angular extrusion (ECAE), also called equal channel angular pressing (ECAP)
has been used to produce ultraine-grained materials [10–12]. ECAP is a convenient forming
procedure to extrude material by the use of specially designed channel dies without a sub-
stantial change in geometry [13]. Extrusion by ECAP method enables obtaining of a ine-grain
structure in larger volumes. There has been a signiicant progress in the use of ECAP from
ordinary metal processing method to well establish procedure for ultraine grain reinement.
This ultraine grain reinement improved the strength and toughness in metal and alloy. At
present, ECAP is the best developed of all severe plastic deformation (SPD) processing tech-
niques [14–16]. Industrial signiicance is given to production by processing bulk materials
through ECAE. Furthermore, useful tools that can be made use of in the development of new
SPD techniques and improving on the existing ones can be formed through the basic prin-
ciples of ECAE, dealing with the mechanics of setal low and the microstructural evolution.
The mechanical and physical properties of all crystalline materials are determined by several
factors, the average grain size of the material generally plays a very signiicant, and often a
dominant, role. One of the most promising SPD processes is equal channel angular pressing
(ECAP) [10]. Large plastic deformation is involved in ECAP for the deformation of work-piece
in a deforming work-piece. This required moving the work piece through two intersecting
channels—usually at an angle of 90° or 120°—of identical cross sections in a die as shown in
Figure 2. ECAE is an efective method of producing a large amount of simple shear defor-
mation in a material by passing it around a corner of two intersecting channels with equal
cross-sections as seen in Figure 2. The major advantage of ECAE over normal extrusion is
that the cross section of the material undergoing ECAE remains the same after the process.
The material can be passed through the same die to repeat the process and accumulate higher
plastic deformation [17]. Segal, in order to change the texture of material processed metals by
method of equal channel angular pressing [10, 18, 19]. The microstructural analysis carried out
on materials that passed through the process showed that grain size was reined to nanometer
level [20]. Diferent strain rates during the process of ECAP has been employed to investigate
the evolutional characteristics of the material microstructure [21].
The deformation during the ECAP is a mixed form of shearing deformation and bending
deformation which afect the orientation of grain crystal of the microstructure [22]. Apart
from orientation of grain crystal, low-angular boundary and critical angle of partition grain
have signiicant efect on the low stress during ECAP [23]. A schematic diagram of ECAP
showing its geometry is shown in Figure 3 where P symbolizes the deformation force.
266 Aluminium Alloys – Recent Trends in Processing, Characterization, Mechanical behavior and Applications

Figure 1. SPD processes developed for grain reinement [4].

 Equal Channel Angular Extrusion Characteristics on Mechanical Behavior of Aluminum Alloy 267
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Figure 2. ECAP principles (channel intersecting at 120° and 90°, respectively) [10].

Figure 3. Schematic diagram of an ECAP die showing the inner die angle (∅) and the outer die angle (Ψ) [26].
268 Aluminium Alloys – Recent Trends in Processing, Characterization, Mechanical behavior and Applications

The properties of materials processed by ECAP are strongly dependent on the plastic defor-
mation behavior during pressing [16, 24]. These properties are governed mainly by the inner
die angle ∅ and outer die angle y, the material properties like strength and hardening behav-
ior [11], and process variables such as lubrication and deformation speed [25].

As the billet moves as a rigid body in the vertical channel, all deformation is restricted to a
small area about the channel’s meeting line. The metal is subjected to a simple shear strain
under relative low pressure compared to the traditional extrusion process [25].

During ECAP, the work-piece cross-sectional area remains unchanged; this ensures process
repeatability until the deformation reached a required grain size level. As a result of cumula-
tive nature, high strain can be achieved with multiple passes. In multiple pass, diferent paths
may be employed, such paths include:
i. Path A: the work-piece orientation remains unchanged in successive passes

ii. Path B: the work-piece is rotated by 90° about its longitudinal axis

iii. Path C: the work-piece is rotated by 180° about its longitudinal axis.

2. Aluminum 6063 alloy

Pure aluminum is a ductile and weak material; however the presence of a relatively small
percentage of impurities in aluminum considerably increases its tensile strength and hard-
ness properties [27]. The mechanical properties of aluminum and its alloys also depend on the
amount of work it has been subjected to and not only its purity. The major purpose of work-
ing is to fragment the grains in the aluminum alloy resulting in an increase in tensile strength
and hardness but decrease in ductility [27].

The 6000 series alloys have recently found increased application in automotive and con-
struction industry. Therefore, several research works have been undertaken to strengthen
the alloys either by small addition of copper, magnesium, zinc and/or silicon or by a pre
deformation treatment [35]. There is a great increase in market for extrusion intricate shape,
medium strength and good toughness as a result of development of Al-Mg-Si alloys for light
structures. These developed alloys are required to meet precise tensile properties and fatigue
strength, welding characteristics and formability [28].

Aluminum alloy 6063 commonly referred to as an architectural alloy because is a medium

strength alloy. It is normally used in intricate extrusions. It has a beter surface inish, beter
corrosion resistance, and beter formability than iron, readily suitable to welding and can be
easily anodised.

The principal alloying elements in Al 6xxx series alloys are Mg and Si, both having low solid
solubility in Al at room temperature [29]. The presence of Fe impurities together with Mg
and Si, inluences the material microstructure through the formation of intermetallic parti-
cles, such as Al (Fe,Mn)Si, Mg2Si, and Al3Mg2. It is known that the Fe-rich particles cannot be
 Equal Channel Angular Extrusion Characteristics on Mechanical Behavior of Aluminum Alloy 269
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re-dissolved during homogenization owing to their high melting point (>700°C) this behavior
has helped in improve on the mechanical properties of Al alloy. A range of intermetallic par-
ticle phases, with their crystallographic structures, have been identiied [30]. Distinguishing
between the phases is of importance for aluminum alloy metallurgy, but may be diicult
based purely on cross-sectional microscopy [31].

2.1. Properties of aluminum 6063 alloy

Al 6063 alloy is an extrusion alloy that is heat treatable for strengthening; machinability is con-
sidered to be average for this alloy; likewise, its forming ability, either hot or cold, is good; the
alloy is readily welded by all of the conventional methods; hot working (as with forging) can
be done on this alloy; Cold working characteristics 6063 are good for all conventional forming
methods; it hardens due to aging heat treatment and cold working; its electrical conductivity
is 50% of copper. Al 6063 alloy is called architectural aluminum for two reasons—irstly, it has
good surface inish smoother than other available alloys, and secondly, its strength is approxi-
mately half the strength of 6061, making it suitable in applications where ultimate strength
is not a requirement. This class of Al alloy is classed as “good” for forming and cold working
requirements, “excellent” for anodizing, and “fair” for machining. It has a good resistance to
general corrosion, including resistance to stress-corrosion cracking in the heat treated condi-
tion. The mechanical properties of 6063 aluminum alloy depend greatly on the temper, or heat
treatment, of the material. Some of the physical properties and temper designations of Al 6063
are stated in Tables 1 and 2 respectively.

2.2. Uses of aluminum 6063 alloy

6063 is mostly used in extruded shapes for architecture as discussed above, particularly for
window frames, door frames, and roofs making aluminum 6063 an important extrusion alloy.
It possesses moderate strength and has excellent inishing characteristics. Al 6063 has become
the prime architectural alloy and its response to a wide variety to surface inishes further
demonstrates its versatility therefore inding usage in decorative applications. The corrosion
resistance is very good and the grade is easily welded and brazed, and is heat-treatable as
well. Moreover, Al 6063 is commonly used in decorative applications, pipes and tubings for

Properties Value
Density 2.71 g/cm3

Melting point 600°C

Modulus of elasticity 67G Pa

Electrical resistivity 0.035E−6Ωm

Thermal conductivity 180 W/m K

Thermal expansion 23E−6/K

Table 1. Physical properties of Al 6063 alloy [32].

270 Aluminium Alloys – Recent Trends in Processing, Characterization, Mechanical behavior and Applications

Standard Temper deinition

tempers
F As fabricated. There is no special control over thermal conditions, and there are no mechanical
property limits.

O Annealed. Applies to products that are annealed to obtain the lowest strength temper.

T1 Cooled from an elevated-temperature shaping process and naturally aged.

T4 Solution heat-treated and naturally aged.

T5, T52, T53 Cooled from an elevated temperature shaping process and artiicially

T54, T55 Aged.

T6 Solution heat treated and artiicially aged.

Table 2. Temper designations and deinitions [33].

irrigation systems, lawn furniture, esthetic applications and trim. Alloy 6063 is often used for
electrical applications in the T5, T52, and T6 conditions due to its good electrical conductivity
(the deinition has been shown in Table 2).

3. Equal channel angular extrusion of aluminum 6063 alloy

Up till date, 6063 is widely used in the production of extrusions—long constant-cross-section

structural shapes produced by pushing metal through a shaped die. These include “L” and
“U” shaped channels and angles. The inluence of magnitude of plastic deformation on prop-
erties of metallic materials is connected with increase of internal energy. Due to the result of
non-homogeneity of deformation at ECAE technique the internal energy gain difers at difer-
ent places of formed alloy [34].
ECAE as earlier deined is a technique using severe plastic deformation to produce ultra-ine
grain sizes in the range of hundreds of nanometers to bulk course grained materials [10, 35, 36].
ECAE is performed by pressing Al 6063 alloy billet of material through a die that has two
channels which intersect at an angle. The billet experiences simple shear deformation, at the
intersection, without any precipitous change in the cross section area because the die does not
allow for lateral expansion. This means the billet can be pressed more than once and can be
rotated about the pressing axis during subsequent pressings. A single pass with channels 90°
to each other, induces approximately 1.15 equivalent strains in the billet.
Diferent deformation routes can be applied depending on the billet rotation; these routes are
shown in Table 3. ECAE technique can be applied to commercial pure metals and metal alloys
[37]. The schematic diagrams of these routes are shown in Figures 4 and 5.

3.1. Superplasticity of aluminum alloys via ECAE

The ability of a material to pull out to a high tensile elongation without the development of
necking is termed superplasticity. Superplasticity is usually in the range of 1–10 μm ine grain
 Equal Channel Angular Extrusion Characteristics on Mechanical Behavior of Aluminum Alloy 271
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Routes Description
Route A No rotation of the billet

Route BA Rotated counter clockwise 90° on even number of passes and clockwise 90° on odd number of passes [39]

Route Bc Rotated counterclockwise 90° after every pass

Route C Rotated 180° after ever pass

Table 3. ECAE routes [38].

Figure 4. Schematic illustration of route A and route BA [6].

size. Much iner grain sizes in the near-nanometer range has been achieved in Al-based alloys
in experiments by using an intense plastic straining technique such as equal-channel angular
pressing (ECAP) [40]. Superplastic properties in Aluminum alloys cannot be achieved under
conventional processing conditions. Superplasticity is the ability of a material to undergo very
large uniform neckless tensile deformation normally over 500% elongation prior to failure at a
temperature well below its melting point (Tm) because the deformation mechanisms fall into the
grain boundary sliding (GBS) regime [41, 42] ine grain size of 10 μm [43], high operation tem-
perature of 0.9Tm and slow strain rate are required as for some Al alloy material. The aerospace
industry irst developed the AA2004 (Al-6Cu-0.5Zr) alloy, also known as Supral 100, which
is a good example for superplastic applications [44]. The alloy composition corresponds to a
relatively large addition of zirconium which provides a dispersion of very ine Al3Zr particles
272 Aluminium Alloys – Recent Trends in Processing, Characterization, Mechanical behavior and Applications

Figure 5. Schematic illustration of route BC and route C [6].

that stabilize the wrought structure developed during hot/cold rolling and prevent recrystal-
lization until the onset of superplastic forming [45, 46]. This alloy is a medium strength alloy
with mechanical properties similar to AA6061 and 2219. It is usually used in lightly loaded
or non-structural applications. Automotive industry demands an increasing use of aluminum
alloys to reduce weight so as to improve performance and fuel consumption. However, in
comparison to steel aluminum alloy sheet materials have lower formability in cold stamping
processes. Some aluminum alloy ofers an alternative approach which can be deformed to
quite a high percentage at elevated temperature by the so-called superplastic forming (SPF)
process [45, 46]. Although ine grain size can be achieved in Al alloy through signiicant ther-
momechanical process, it is very costly and also the low deformation strain rate results in long
forming times [6, 47]. Therefore reduction of the grain size in the sub-micrometer or nanometer
scale is usually encouraged by applying Equal-Channel Angular Pressing, or ECAP [48].
Superplasticity has been utilized for the fabrication of complex parts from sheet metal because
of the large elongation [49, 50] There is considerable current interest in developing materi-
als with ultraine grain sizes, since experimental evidences have shown that reducing grain
size increases the superplastic strain rate and/or decreases the superplastic temperature [51].
Materials processed by ECAE have the potential for superplasticity, especially at very high
strain rates and low temperatures. The validity of this proposal has been demonstrated by
several recent reports of high strain rate superplasticity above 10−2 s−1 and low temperature
superplasticity in aluminum and magnesium alloys processed by ECAE [52–55].
 Equal Channel Angular Extrusion Characteristics on Mechanical Behavior of Aluminum Alloy 273
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4. Conclusions

From the current review, it can be concluded that severe plastic deformation via ECAP is a very
useful process on increasing mechanical properties with only partial and acceptable decrease
in ductility. Strengthening of material was caused by grains reinement and strain hardening of
solid solution. Because the cold-worked material was a normal material that has already been
extended through part of its allowed plastic deformation by ECAE, dislocation motion and
plastic deformation have been hindered enough by dislocation accumulation, and stretching of
electronic bonds. Elastic deformation then reached their limit, a third mode of deformation then
occurs faster (i.e. fracture). Strain hardening thus reduces ductility and increases britleness.
Processing by ECAE led to grain reinement and arrays of ultraine grains that are signii-
cantly smaller than those generally produced using conventional thermo mechanical process-
ing. ECAE is a simple process that can be readily applied to a wide range of materials without
the requirement of developing speciic and diferent treatments for each alloy composition.
The presence of these exceptionally small grain sizes provides an opportunity for achieving
superplastic ductility, and thus a superplastic forming capability at a very fast strain rates
(extremely higher than what was used in the experiment).

Author details

Abiodun Ayodeji Abioye1, Ojo Sunday Isaac Fayomi1,2*, Abimbola Patricia Idowu Popoola2
and Oluwabunmi Pamilerin Abioye1

*Address all correspondence to: [email protected]

1 Department of Mechanical Engineering, Covenant University, Ota, Ogun State, Nigeria

2 Department of Chemical, Metallurgical and Materials Engineering, Tshwane University of

Technology, Pretoria, South Africa

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