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[Beta] phase growth and precipitation in the 5xxx series aluminum alloy system
Dissertation   Open access

[Beta] phase growth and precipitation in the 5xxx series aluminum alloy system

Daniel Scotto D'Antuono
Doctor of Philosophy (Ph.D.), Drexel University
May 2017
DOI:
https://doi.org/10.17918/etd-7426
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Abstract

Aluminum alloys--Corrosion Transmission electron microscopy Composite Materials Materials Science
The 5xxx series aluminum alloys are commonly used for structural applications due to their high strength to weight ratio, corrosion resistance, and weldability. This material system is a non-heat treatable aluminum and derives its strength from a super saturation of magnesium (3%>), and from cold rolling. While these materials have many admiral properties, they can undergo a process known as sensitization when exposed to elevated temperatures (50-280°C) for extended periods of time. During this process, magnesium segregates toward the grain boundaries and forms the secondary precipitate [beta] phase (Al3Mg2). When exposed to harsh environments such as sea water, a galvanic couple is formed between the Al matrix and the [beta] phase precipitates. The precipitates become anodic to the matrix and preferentially dissolve leaving gaps along the boundary network, ultimately leading to stress corrosion cracking. While this problem has been known to occur for some time now, questions relating to nucleation sites, misorientation dependence, effect of prior strain, and preferred temperature regimes remain unanswered. The work contained in this thesis attempted to better understand the kinetics, growth, and misorientation dependence, of [beta] phase precipitation using in situ transmission electron microscopy experiments which allowed for direct visualization of the precipitation process. Orientation imaging using a Nanomegas/ASTAR system (OIM in TEM) coupled with the in situ experiments, along with elemental STEM EELs mapping were used to better understand the diffusion of Mg and found low angle boundaries as potential sites for nucleation. The resulting STEM EELs experiments also showed that Mg is much more stable at the grain boundaries than previously thought. Concurrent bulk ex-situ studies were used to compare various heat treatments, as well as to failed in service material showing that the low temperature treatments yield the metastable [beta]' phase more readily than the [beta] equilibrium phase. The work here has identified the size, location, and kinetics of [beta] phase formation as well as the effects of pre-strain (cold rolling) and boundary misorientation on precipitation showing that increases in dislocations speeds up sensitization and increases nucleation sites but does not increase overall precipitate size. This work also compared precipitate type ([beta] vs. [beta]') showing that the metastable [beta]' phase is more common in low temperature treated material and the main precipitate found in failed in service material. A comparison between the corrosion effects of the two precipitation showed that lower temperature treatments have a higher degree of sensitization further delineating between the two forms.

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