Microstructure evolution, mechanical properties, and strengthening mechanisms of 6061 aluminum alloy processed via corrugated constrained groove pressing.

In this study, a corrugated constrained groove pressing (CCGP) technology based on a semicircle groove was proposed, improving the uniformity of strain accumulation in deformed metal sheets through staggered groove pressing. First, 6061-O aluminum alloy was processed at room temperature via conventional CCGP (Conv-CCGP) and 90° cross CCGP (Cross-CCGP). The effects of strain route and deformation pass on the microstructure evolution of the CCGPed alloy were investigated and correlated with mechanical properties. Changes in the mechanical properties of the CCGPed alloy at room temperature measured via tensile in different directions and hardness tests were studied. Results showed that the strength and hardness of the CCGPed sheet in both routes were considerably improved, but ductility was decreased. Cross-CCGP can effectively alleviate the anisotropy of the deformed sheet and achieve optimal strength in roll direction (RD) and transverse direction (TD) at two passes. Yield strength (YS) and ultimate tensile strength (UTS) along RD were increased by 190.2% and 15.5% relative to the initial alloy, reaching 119 MPa and 134 MPa, respectively. Along TD, YS and UTS were increased by 255.0% and 36.0%, reaching 142 MPa and 151 MPa, respectively. Characterization techniques, including electron backscatter diffraction and high-resolution transmission electron microscopy, were used to establish comprehensive models of dynamic recovery-based substructure evolution and dynamic recrystallization-dominated grain refinement. Meanwhile, the integrated microstructural changes and theoretical calculations identified dislocation strengthening and local grain refinement as the major contributors to the strengthening of the CCGPed alloy. In addition, tensile fracture surface analysis showed that the CCGPed alloy still underwent plastic fracture, but the fracture mode shifted from tension fracture into shear fracture. • A CCGP technology to uniform strain by staggered groove pressing was proposed. • CCGPed sheets show significant improvement in microhardness, YS and UTS. • Combined models of substructure evolution and grain refinement were developed. • Dislocations and local grain refinement on enhancement of strength were discussed. • The tensile fracture mechanisms of the CCGPed alloy were analyzed. [ABSTRACT FROM AUTHOR]