The Effect of Direct- and Cross-Rolling on Mechanical Properties and Microstructure of Severely Deformed Aluminum

The Effect of Direct- and Cross-Rolling on Mechanical
Properties and Microstructure of Severely Deformed
Aluminum
K.Rahimi Mamaghani and M. Kazeminezhad
(Submitted October 14, 2012; in revised form October 2, 2013; published online October 17, 2013)
Severely deformed commercial pure aluminum sheets by constrained groove pressing are direct and cross-
rolled. The grain size evolution and dislocation density during rolling are studied using Williamson-Hall
analysis on x-ray diffraction patterns of the deformed samples. These results and optical microscopy
observations show that subsequent direct or cross-rolling of constrained groove pressed aluminum can
produce elongated fine grains. The minimum crystallite size is achieved after cross-rolling of constrained
groove pressed samples. By direct-rolling or cross-rolling of annealed sheet, the maximum intensity in x-ray
diffraction patterns remains on (200) like annealed aluminum but direct-rolling or cross-rolling of con-
strained groove pressed sheets changes the maximum intensity from (111) for constrained groove pressed
sheets to (220). Also, mechanical properties are studied using tensile test and hardness measurement. The
results show that cross-rolling on constrained groove pressed samples is more effective than direct-rolling in
mechanical properties improvement.
Keywords cross-rolling, direct-rolling, microstructure, severe
plastic deformation, x-ray diffraction
1. Introduction
Ultrafine-grained materials are attended during recent years.
They have unique combination of physical and mechanical
properties compared with those of coarse-grained materials
(Ref 1, 2). Also, obtaining nanostructure is a very effective way
of increasing material strength; especially the case of light
alloys such as aluminum is of great interest as the strength is
significantly increased with grain refinement. This leads to an
improvement in the strength to weight ratio, which is a
desirable property for transportation and aerospace industries
(Ref 3). Several methods of producing nanostructured materials
by severe plastic deformation (SPD) have been developed.
In 2002, Shin et al. Ref 4 invented a SPD process of sheet;
constrained groove pressing (CGP) process consists of repet-
itive shear deformation under plane strain deformation condi-
tion by utilizing alternate pressings with grooved and flat dies
(Ref 4-7). In this study, CGP method is used for imposing the
SPD to the aluminum sheets. Since this method has been
recently invented, there are no further works on it and it seems
that more works should be carried out. To produce severely
deformed thin sheets, the severely deformed ones should be
rolled, because, during SPD of thin sheets, the sheets may be
ruptured due to large loads. Thus, one of the possible ways of
treatments is sheet rolling. Sheets can be used in different
industries. This treatment is reasonable in case of preservation
and improving nanostructures and related physical and
mechanical properties in the sheets.
The effects of rolling after SPD on properties and micro-
structure have been studied for copper, steel, aluminum alloy,
titanium, and titanium alloy (Ref 8-14). It was shown that
rolling after equal channel angular pressing (ECAP) results in
further grain refinement and improving strength. In particular,
the effects of direct and cross-rolling strains on microstructure
and mechanical properties of CGPed samples have not yet been
studied. Thus, understanding the correlation between micro-
structure and properties of material after CGP and, after direct
and cross-rolling of CGPed samples with different reductions in
cross-section is an interesting subject.
The aim of current research is on investigation of micro-
structure and mechanical properties of aluminum after different
strains of CGP and subsequent direct and cross-rolling with
different reductions in cross-section. Also, the effects of rolling
and cross-rolling on annealed and CGPed materials are studied.
2. Experimental Procedure
In the present study, annealed (at 623 K for 3 h) commercial
pure aluminum sheets (AA1100) with dimension of 84 mm 9
60 mm 9 3 mm were used to study the effectiveness of CGP+
rolling processes for grain refining and strengthening of
aluminum sheets. The details of process procedure can be
found in Ref 15-17 consisting of pressings in corrugated and
flattened dies.
However, it should be noted that the width of corrugating
dents of grooving dies is equal to the sheet thickness that
reveals pure shear deformation condition through the process.
K.Rahimi Mamaghani and M. Kazeminezhad, Department of
Materials Science and Engineering, Sharif University of Technology,
Azadi Avenue, Tehran, Iran. Contact e-mail: mkazemi@sharif.edu.
JMEPEG (2014) 23:115–124 ÓASM International
DOI: 10.1007/s11665-013-0742-5 1059-9495/$19.00
Journal of Materials Engineering and Performance Volume 23(1) January 2014—115

In this study, Teﬂon layers between aluminum sheet and dies
were used as lubricant. The pressing force of process was
supplied using a 1000 kN hydraulic pressing machine at a ram
speed of 0.05 mm/s. The applied load in this process was
around 30-40 KN. The CGPed aluminum sheets with different
strains were rolled at room temperature using different rolling
reductions with rolls speed of 30 rpm. A laboratory 20 tons
capacity rolling machine with two cylindrical rolls of 150 mm
diameter was utilized. The CGPed sheet thickness was 3 mm,
in each rolling pass its thickness was reduced 0.5 mm and this
reduction continued until the sheet thickness of 0.5 mm was
achieved. The mechanical and microstructural examinations
were performed on 1.5 mm (rolling strain of 0.8), 1 mm
(rolling strain of 1.27), and 0.5 mm (rolling strain of 2.07)
thickness sheets. Direct-rolling was carried out in longitudinal
direction of CGPed aluminum and cross-rolling was performed
with 90° rotation.
To investigate the microstructure evolution of sheets during
process, x-ray diffraction (XRD) measurements were carried
out on a Philips x-ray diffractometer equipped with a graphite
Fig. 1 Metallographic images of (a) annealed Al sheet, (b) 2 passes CGPed Al
Fig. 2 Metallographic images of deformed Al with 1.27 rolling strain: (a) direct-rolled annealed Al, (b) direct-rolled 2 passes CGPed Al, (c)
cross-rolled annealed Al, (d) cross-rolled 2 passes CGPed Al
116—Volume 23(1) January 2014 Journal of Materials Engineering and Performance

monochromator using Cu Ka radiation. The x-ray patterns of
samples were obtained in the range of 10°-80° and in the step
width of 0.02°. For calibration of the instrumental line
broadening, SiC powder was examined in the same condition.
Resolving full-width at half-maximum (FWHM) for all peaks
was carried out using the software configured with the XRD
system. The XRD patterns were achieved from center of the
samples. An approved reliable based-model approach of XRD
line profile analysis that utilized in this study was Williamson-
Hall method (Ref 18, 19). Correspondingly, crystallite size and
lattice equivalent strain can be resolved by measuring the
deviation of line profile from perfect crystal diffraction. In the
Williamson-Hall method, there is a relation between FWHM
(b), crystallite size (t), and the distortion function (f(e))
(explained in Ref 19, 20), by the following equation (Ref 20):
bcosh ¼
kk
t
þ f eð Þsinh ðEq 1Þ
where h is the Bragg angle, k is the wavelength, and k is the
Scherer constant (%0.9). Considering Eq 1, the intercept of
the plot b cos h versus sin h gives the cell size and the slope
gives the crystal strain.
Fig. 3 Metallographic images of (a) direct-rolled annealed Al with 0.8 rolling strain, (b) direct-rolled annealed Al with 2.08 rolling strain, (c)
direct-rolled 1 pass CGPed Al with 0.8 rolling strain, (d) direct-rolled 1 pass CGPed Al with 2.08 rolling strain, (e) direct-rolled 3 passes CGPed
Al with 0.8 rolling strain, (f) direct-rolled 3 passes CGPed Al with 2.08 rolling strain

Commercial diffractometer contains the instrumental
profile besides the intrinsic profile (pure diffraction profile).
In this regard, the Gaussian-Gaussian function can be
employed to correct the integral breadths of intrinsic profile
(Ref 19).
b2
exp ffi b2
þ b2
ins ðEq 2Þ
where b, bexp, and bins are the integral breadth of the intrin-
sic, experimental and instrumental profiles, respectively. The
value of the dislocation density was calculated (Ref 21, 22)
from the average values of the crystallite size (t) and micro-
strain (eL) by the following equations:
q ¼
ffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
qt Â qS
p
ðEq 3Þ
qt ¼
3
t
ðEq 4Þ
qS ¼
K < e2
L >
b2
ðEq 5Þ
where K = 6p and b is the Burgers vector ( b ¼ a=
ffiffiffi
2
p
for
FCC structure and a is the lattice parameter, which can be
considered 4.097 A˚ for aluminum).
Optical microscope observations were carried out on the
processed specimens. Samples in thickness direction were
Fig. 4 Metallographic images (a) cross-rolled annealed Al with 0.8 rolling strain, (b) cross-rolled annealed Al with 2.08 rolling strain, (c)
cross-rolled 1 pass CGPed Al with 0.8 rolling strain, (d) cross-rolled 1 pass CGPed Al with 2.08 rolling strain, (e) cross-rolled 3 passes CGPed
Al with 0.8 rolling strain, (f) cross-rolled 3 passes CGPed Al with 2.08 rolling strain

polished then electro-chemically etched with BarkerÕs etchant
(2.5% HBF4 solution, and a voltage of 20 V DC applied for
duration of 2 min) and then viewed under polarized light
illumination (Ref 23). The optical microscopy of annealed
sample showed extremely large average grain size of 100 lm.
Also, to investigate the mechanical behavior of aluminum
sheets after CGP and rolling in different directions, tensile, and
hardness tests were carried out. Tensile test specimens were
machined according to the ASTM E8M standard that the gage
length was aligned along the longitudinal direction of the
pressed sheet. Room temperature tensile tests were performed on
an Instron machine operating at an initial strain rate of 5 9 10À3
/
s. Also, Vickers hardness measurements were carried out on the
longitudinal sections along the length of the specimen. A 5 kg
load applied for 30 s was utilized for these measurements in all
samples. The hardness values were achieved from the average of
10 measurements on each specimen.
3. Results and Discussion
3.1 Microstructure
3.1.1 Optical Microscope Observations. The micro-
structure of annealed sample shows equiaxed grains (Fig. 1a).
Figure 1(b) shows the microstructure of the groove-pressed
aluminum after two CGP passes. CGP changes the microstruc-
ture of material by imposing shear force; however, as shown in
Fig. 1(b), deformed microstructure of CGPed sample approx-
imately preserves its initial equiaxed grain structure. There is a
noticeable reduction in grain size after CGP (Ref 4-7).
The microstructures of the cold-rolled annealed and CGPed
aluminum sheets are shown in Fig. 2. In both CGPed and
annealed aluminum sheets, lamellar microstructures are
observed after direct and cross-rolling. The cold rolling process
of CGPed sheets leads to the elongated finer grains than those
of annealed ones (Ref 24). After rolling, the grains of CGPed
samples become narrower than those of annealed ones because
of initial strain and grain refinement.
There is not a lot of difference in microstructures of direct-
rolled and cross-rolled annealed sheets as can be seen in
Fig. 2(a) and (c). But, the narrower and finer microstructure is
observed in cross-rolled CGPed sheet than that in direct-rolled
one, Fig. 2(b) and (d).
Figure 3(a) and (b) show the effect of rolling strain on the
microstructures of annealed aluminum. With increasing the
deformation amount in cold-rolling, the microstructure be-
comes more laminate and the grains are elongated along the
rolling direction (Ref 25, 26). More information about the
structure and properties of cold-rolled commercial purity
aluminum in rolling strain of 2 can be found in Ref 27-30.
Figure 3 (c), (d), (e), and (f) show the effect of rolling strain
on the microstructures of CGPed aluminum. In both rolling
directions (Fig. 3 and 4) the structures show the space between
the lamellar boundaries has decreased with increasing rolling
strain. Comparing these images represent that increase in the
pass number of CGP makes more laminar and finer micro-
structure. This is more obvious in less CGP pass or low rolling
strain.
3.1.2 Crystallite Size. During severe plastic deformation,
subgrain boundaries evolve in the grains structures (Ref 31).
Subsequently, these boundaries develop areas with coherent
crystalline domain size (Ref 32). After analyzing the XRD
pattern of each sample using Williamson-Hall method, evolu-
tion of cell/crystallite size during rolling of CGPed aluminum
sheet is calculated and shown in Fig. 5 for two passes CGPed
sheet. As can be seen after two passes of CGP (i.e., at zero
rolling strain), the coarse-grained annealed aluminum is
transformed to a microstructure with cell size of 960 nm which
is consistent with the result presented in Ref 33.
However, after CGP, by subsequent rolling, the cell/
crystallite size has decreased according to the rolling strain. It
should be noted that in direct-rolling, the rate of refining is
nearly linear and in cross-rolling more rapid refinement can be
observed. In the constant rolling strain, the cell/crystallite size
of cross-rolled CGPed aluminum is finer than that of direct-
rolled one. These results can be confirmed by the metallo-
graphic images presented in Fig. 3 and 4 showing the grain
refinement and formation of a lamellar structure at large rolling
strain of CGPed aluminum.
The cell/crystallite size of cross-rolled two passes CGPed
aluminum with 2.07 rolling strain is about 670 nm which is
730 nm for direct-rolled one. However, there is difference
between the calculated sizes and actual ones. The difference
can become from Scherer constant of $0.9 assumed in
calculations which is for spherical morphology, while here
the morphology is elongated.
Fig. 5 The effects of direct-rolling and cross-rolling strain on crys-
tallite size of 2 passes CGPed aluminum
Fig. 6 The effects of direct-rolling and cross-rolling strain on dislo-
cation density of 2 passes CGPed aluminum

Fig. 7 XRD proﬁles of (a) annealed Al, (b) 2 passes CGPed Al, (c) direct-rolled annealed Al with 1.27 rolling strain, (d) cross-rolling annealed
Al with 1.27 rolling strain, (e) direct-rolled 2 passes CGPed Al with 1.27 rolling strain, (f) cross-rolled 2 passes CGPed Al with 1.27 rolling
strain

3.1.3 Dislocation Density. It is possible to calculate the
variation of dislocation density versus imposed rolling strain
(Ref 19). Figure 6 shows the dislocation densities of two passes
CGPed aluminum sheet versus direct and cross-rolling strains
that calculated using Eqs 3, 4, and 5. After a specific rolling
strain, the rate of dislocation generation has decreased, which
may arise from annihilation of dislocations due to restoration
phenomena. The amount of dislocation density after cross-
rolling is more than that after direct-rolling. It can be observed
that the dislocation density reaches to a plateau in lower strain
through cross-rolling than that in direct-rolling. It will be shown
that the variations of hardness and the mechanical properties
versus rolling strain of three passes CGPed aluminum have the
similar trend.
3.2 X-ray profiles Analysis
Figure 7 shows XRD profiles on the surfaces of direct-rolled
and cross-rolled CGPed aluminum obtained in 1.27 rolling
strain and annealed specimen.
Table 1 lists the intensities of (111), (200), (220), and (311)
peaks to the strongest peak intensity, which is measured from
XRD profiles shown in Fig. 7.
Figure 7(a), (c), (e) and Table 1 show that the plane with
higher intensity remains constant after direct-rolling or cross-
rolling of coarse-grained aluminum (annealed).
Figure 7(a) and (b) shows that the intensities of the peaks
observed in the starting material are changed after CGP; which
is related to the large plastic deformation and microstructural
changes involved in the CGP. Comparing CGP sample with
annealed one reveals that the intensity of (200) has reduced and
instead the intensity of (111) has increased. The increasing
intensity of the (111) peak which is the major slip plane of FCC
metals (Ref 34) indicates that the process induces shear stress
(Ref 35). With increasing the CGP pass, the grain size has
gradually refined and width of diffraction peak in XRD pattern
has broadened (Ref 36).
Direct-rolling or cross-rolling of CGPed sheets changes the
maximum intensity from (111) to (220). By direct-rolling or
cross-rolling of annealed sheet, the maximum intensity remains
on (200). This is due to the different deformation paths.
Table 1 shows that in cross-rolling of CGPed aluminum, the
ratio of the intensity of (220) peak to the intensities of other
peaks is more than that for direct-rolling of CGPed aluminum.
This reveals that a stronger (220) plane orientation developed in
the early stages of cross-rolling, which is indicative of a
dominance of dislocation processes during this stage of the
deformation process (Ref 37).
With increase in the strain of direct-rolling or cross-rolling
(220) peak becomes stronger. This trend reveals that the
preferred plane orientation owning to direct-rolling or cross-
rolling of CGPed aluminum is (220) as seen in Table 2.
Broadening of all peaks occurs due to the refinement of the
microstructure according to the rolling strain. The increase in
the dislocation density of aluminum leads to the decrease in the
intensity of peaks.
The results in Table 2 show that the ratio of the intensity of
(220) to the intensities of other peaks is strongly increased with
increasing the direct-rolling strain, but in cross-rolling at high
strains, it is reduced. It is anticipated that the local deformation
mechanisms such as grain rotation and grain boundary sliding
can become active (Ref 38).
Table 1 The intensity ratios of each peak to the strongest peak for direct-rolled and cross-rolled of annealed and CGPed
profiles
I
Imax
(311) (220) (200) (111)
Annealed Al 33.41 64 100 44.28
Direct-rolling of annealed Al with 1.27 rolling strain 58.81 36.92 100 58.45
Cross-rolling of annealed Al with 1.27 rolling strain 39.73 78.38 100 45.29
2 passes CGPed Al 47.42 50.71 90.36 100
Direct-rolling of 2 passes CGPed Al with 1.27 rolling strain 78.83 100 45.5 37.96
Cross-rolling of 2 passes CGPed Al with 1.27 rolling strain 41.62 100 28.7 21.17
The bold values indicate the strongest peaks
Table 2 The intensity ratio of each peak to the intensity of the strongest peak for direct-rolled and cross-rolled of CGPed
sheets with different rolling strains
I
Imax
(311) (220) (200) (111)
2 passes CGPed Al 47.42 50.71 90.36 100
Cross-rolling of 2 passes CGPed Al with 0.8 rolling strain 58.22 89.5 100 62.98
The bold values indicate the strongest peaks

3.3 Mechanical Properties
3.3.1 Tensile Properties. Figure 8 shows the effect of
rolling strain on ultimate tensile strength (UTS), yield strength
(YS), and elongation at different CGP passes. The UTS and YS
of the aluminum have increased and the ductility has decreased
with increasing CGP pass (Ref 33). The CGPed aluminum
tensile properties are similar to those reported previously (Ref
4, 33). By subsequent rolling, the strength of sheet has
increased and elongation hass decreased. The tensile properties
are closely related to the characteristics of deformed micro-
structures shown in Fig. 4 and 5.
The tensile strength of annealed aluminum has increased
from 68 to 187 MPa after the 2.07 rolling strain in direct-rolling
and to 190 MPa in cross-rolling. It shows that the direct-rolling
and cross-rolling have no different effects on the strength.
In cross-rolling of CGPed aluminum, the increase of UTS
versus rolling strain is more rapid than that for direct-rolling of
CGPed aluminum which is consistent with higher dislocation
density and ﬁner microstructure of cross-rolled specimen
discussed before.
A comparison between direct-rolling and cross-rolling of
CGPed aluminum shows that with increasing rolling strain,
Fig. 8 (a) The UTS of direct-rolled, (b) the UTS of cross-rolled, (c) the YS of direct-rolled, (d) the YS of cross-rolled, (e) the elongation of di-
rect-rolled, (f) the elongation of cross-rolled annealed and CGPed Al vs. rolling strain

cross-rolling is more effective in improving the mechanical
properties of CGPed aluminum that it is not seen for direct-
rolling and cross-rolling of annealed aluminum. This is in good
accordance with microstructure and XRD results. In direct-
rolling of two passes CGPed aluminum, the UTS has increased
to 192 MPa in 2.07 rolling strain and for cross-rolling with the
same condition UTS has increased to 223 MPa that which is
3.3 times greater than UTS of the starting annealed aluminum
(68 MPa).
The elongation of annealed aluminum has decreased from
48 to 8% after the first pass of CGP. With subsequent direct-
rolling or cross-rolling, it has decreased with increasing rolling
strain. By cross-rolling of three passes, CGPed aluminum to
2.07 rolling strain, the elongation reaches to 2%.
3.3.2 Hardness. Hardness of annealed and CGPed alu-
minum as a function of rolling strain is shown in Fig. 9. The
results for CGPed specimens are consistent with the result
presented in Ref 33.
Figure 9 shows an immediate increase in hardness up to the
rolling strain of 1.27 and then no significant changes can be
seen.
The results of hardness measurements confirm the results
achieved from microstructure and tensile properties studies of
the specimens through direct- and cross-rolling.
4. Conclusions
The conclusions of this study can be presented as:
1. Applying the direct-rolling and cross-rolling process on
CGPed aluminum is successfully possible up to high roll-
ing strain, and this can be done as a further deformation
on CGPed material.
2. With increasing the rolling strain, the grains become finer
and more elongated. An increase in the pass number of
initial CGP makes the microstructure more laminar and
finer. The cross-rolling of CGPed aluminum leads to the
finer grains than those achieved in direct-rolling of
CGPed aluminum
3. There is neither a lot of difference in microstructure nor
mechanical properties of direct-rolling and cross-rolling
of annealed aluminum. The cross-rolling of CGPed alu-
minum leads to better mechanical properties and finer
microstructure in comparison with those in direct-rolling
of CGPed aluminum.
4. The amount of dislocation density increases with increas-
ing the rolling strain. Dislocation density after cross-roll-
ing is more than that after direct-rolling,
5. After CGP, subsequent rolling leads to a finer crystallite
size. The crystallite size of cross-rolled CGPed aluminum
is finer than that of direct-rolled one. The minimum crys-
tallite size of 670 nm is achieved in cross-rolled two
passes CGPed aluminum with 2.07 rolling strain.
6. Direct-rolling or cross-rolling of CGPed sheets changes
the maximum intensity from (111) to (220). By direct-
rolling or cross-rolling of annealed sheet, the maximum
intensity remains on (200) like annealed aluminum.
Acknowledgment
The authors wish to thank the research board of Sharif
University of Technology for the financial support and the
provision of the research facilities used in this work.
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