Microstructural Tailoring of Ultrafine-Grained Magnesium Alloys for Lightweight Applications

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There is an increasing demand on the aerospace and automotive industries to reduce weight, fuel consumption and emission of greenhouse gases by using lightweight materials such as Magnesium (Mg) and Aluminum (Al). Also, lightweight materials, that are resistant to shock loading, are needed in protective vehicles and personnel armour to prevent injury. Magnesium (Mg) is the lightest metal and Mg alloys are desired for lightweight applications due to their low density (~1738 kg/m3, ~35% < Al). However, Mg alloys exhibit poor formability, moderate strength and limited ductility due to their hexagonal close-packed crystal structure. Ultrafine-grained (UFG) materials (grain sizes ~ 1000 nm) possess unique microstructure-dependent properties superior to coarse-grained materials. They are produced through grain refinement and have enhanced properties such as high strength and fracture toughness. Severe Plastic Deformation (SPD) techniques such as high pressure torsion can be used to produce bulk UFG Mg alloys with exceptional strength, fracture toughness and ductility. During SPD, very high strains (true strain 1) are imposed on a bulk material leading to exceptional grain refinement without significant change to the overall dimensions of the material. Also, large amounts of lattice defects such as grain boundaries and dislocations are formed that improve the deformation behavior of the materials.This research implements a synergistic approach involving the development and comprehensive physical, mechanical and microstructural characterization of UFG Mg alloys. Bulk UFG Mg alloys will be developed and mechanisms that occur during the evolution of ultrafine grains and lattice defect structures in the alloys will be studied. The mechanism/s that occur during grain refinement, their effect on the evolved microstructure and optimum processing conditions will also be studied. The dynamic mechanical properties, deformation behavior and mechanism of damage of UFG Mg alloys will be characterized at intermediate (10-100 /s) to high strain rates (1000 /s). Mechanisms that govern damage accumulation including the sequence of events that occur during strain localization and formation of ASBs will be studied. Constitutive equations and material parameters to accurately describe the properties and dynamic deformation behavior of the UFG Mg alloys will be developed.The comprehensive experimental data, constitutive equations and predictive computational models will be invaluable in tailoring the properties of lightweight materials and form the basis for future innovative developments in lightweight technologies. In addition, this research will train highly qualified personnel with exceptional skills in material processing and characterization including electron microscopy and computational modeling currently needed by employers in the automotive and aerospace industries.