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This study investigated the effect of adding Al–5Ti–1B grain refiner on the solidification microstructure and hot deformation behavior of direct-chill (DC) cast Al–Zn–Mg–Cu alloys. The grain refiner significantly decreased the grain size and modified the morphology. Fine-grained (FG) alloys with grain refiners exhibit coarse secondary phases with a reduced number density compared to coarse-grained (CG) alloys without grain refiners. Dynamic recrystallization (DRX) was enhanced at higher compression temperatures and lower strain rates in the CG and FG alloys. Both particle stimulated nucleation (PSN) and continuous dynamic recrystallization (CDRX) are enhanced in the FG alloys, resulting in decreased peak stress values (indicating DRX onset) at 450°C. The peak stress of the FG alloys was higher at 300-400°C than that of the CG alloys because of grain refinement hardening over softening by enhanced DRX.

Twinned dendrites in Al-Zn alloy with high Zn content (40% wt.%) were successfully prepared by directional solidification. At different directional solidification rates (1000 and 1500 μm/s), microstructures and growth orientation variations of Al twinned dendrite and non-twinned dendrite were characterized. By using the inverted trapezoidal graphite sleeve at 1000 μm/s, Al twinned dendrite were formed to developed feather crystal structures in longitudinal section. Its primary and secondary twinned dendrite were grew along [110] direction. Moreover the deviation angle between [110] direction of Al twinned dendrite and the heat flow direction was about 27.15°. While not using the inverted trapezoidal graphite sleeve at 1000 and 1500 μm/s, Al dendrite was the non-twinned dendrite and the twinned dendrite was not appeared. The experimental results showed that the higher temperature gradient, a certain pulling rate and convection environment were the formation conditions of twinned dendrites.

Twinned dendrites in Al-Zn alloy with high Zn content (40% wt.%) were successfully prepared by directional solidification. At different directional solidification rates (1000 and 1500 μm/s), microstructures and growth orientation variations of Al twinned dendrite and non-twinned dendrite were characterized. By using the inverted trapezoidal graphite sleeve at 1000 μm/s, Al twinned dendrite were formed to developed feather crystal structures in longitudinal section. Its primary and secondary twinned dendrite were grew along [110] direction. Moreover the deviation angle between [110] direction of Al twinned dendrite and the heat flow direction was about 27.15°. While not using the inverted trapezoidal graphite sleeve at 1000 and 1500 μm/s, Al dendrite was the non-twinned dendrite and the twinned dendrite was not appeared. The experimental results showed that the higher temperature gradient, a certain pulling rate and convection environment were the formation conditions of twinned dendrites. [ABSTRACT FROM AUTHOR]

Based on the twin planes formed at 3000 μm/s, the growth stability of twinned dendrites in Al-4.5 wt% Cu alloy was studied in detail at a low growth rate during Bridgman solidification. Experimental results show that the twinned dendrite growth could still keep stable even after decreasing the rate to 20 μm/s. This is far below the usual rate threshold for the formation of twinned dendrites (∼1000 μm/s). The dominated twinned structures at 20 μm/s have their (1 1 1) twin plane and 〈1 1 0〉 dendritic trunk closest to thermal gradient direction. Importantly, distinct stacking fault (SF) structures directly connecting two adjacent twin boundaries provide a direct experimental evidence for the close correlation between the SFs and the twinned dendrite growth in aluminum alloys. [ABSTRACT FROM AUTHOR]