THE EFFECT OF LOW MELTING POINT IMPURITIES ON THE PROPERTIES OF Al-Li ALLOYS D. Webster To cite this version: D. Webster. THE EFFECT OF LOW MELTING POINT IMPURITIES ON THE PROPERTIES OF Al-Li ALLOYS. Journal de Physique Colloques, 1987, 48 (C3), pp.C3-685-C3-691. <10.1051/jphyscol:1987379>. <jpa-00226610> HAL Id: jpa-00226610 https://hal.archives-ouvertes.fr/jpa-00226610 Submitted on 1 Jan 1987 HAL is a multi-disciplinary open access archive for the deposit and dissemination of scientific research documents, whether they are published or not. The documents may come from teaching and research institutions in France or abroad, or from public or private research centers. L’archive ouverte pluridisciplinaire HAL, est destinée au dépôt et à la diffusion de documents scientifiques de niveau recherche, publiés ou non, émanant des établissements d’enseignement et de recherche français ou étrangers, des laboratoires publics ou privés. JOURNAL DE PHYSIQUE C o l l o q u e C 3 , s u p p l 6 m e n t au n 0 9 , Tome 48, s e p t e m b r e 1 9 8 7 THE EFFECT OF LOW MELTING POINT IMPURITIES ON THE PROPERTIES OF A1-Li ALLOYS D . WEBSTER K a i s e r Aluminum a n d C h e m i c a l C o r p o r a t i o n , P.O. P l e a s a n t o n , C A 94566, U . S . A . Box 877, Abstract The e f f e c t of low m e l t i n g p o i n t i m p u r i t i e s , s u c h a s sodium a n d p o t a s s i u m , o n t h e p r o p e r t i e s a n d m i c r o s t r u c t u r e o f A1-Li a l l o y s h a s been i n v e s t i g a t e d . T h e s e i m p u r i t i e s have b e e n shown t o o c c u r a s d i s c r e t e l e n t i c u l a r p a r t i c l e s along g r a i n boundaries. I n underaged a n d peak-aged c o n d i t i o n s , t h e impurity p a r t i c l e s a r e l i q u i d and t h e t o u g h n e s s a n d d u c t i l i t y o f a l l o y s i n t h i s c o n d i t i o n were found t o be improved by l o w e r i n g t h e t e s t t e m p e r a t u r e below t h e f r e e z i n g p o i n t o f t h e impurity. I n t h e overaged c o n d i t i o n , t h e sodium a n d p o t a s s i u m o c c u r a s a s o l i d p h a s e a n d m a t e r i a l s i n t h i s c o n d i t i o n were f o u n d t o f o l l o w t h e p a t t e r n o f most aluminum a l l o y s a n d show a d e c r e a s e i n C h a r p y i m p a c t t o u g h n e s s a s t h e t e s t i n g t e m p e r a t u r e was l o w e r e d . The a d d i t i o n o f sodium a n d p o t a s s i u m t o A1-Li a l l o y s r e d u c e d t o u g h n e s s a n d d u c t i l i t y a t room t e m p e r a t u r e i n t h e r a n g e o f c o m p o s i t i o n s Low m e l t i n g i n v e s t i g a t e d ( u p t o 476 ppm Na a n d up t o 23 ppm K ) . p o i n t i m p u r i t i e s were found t o have l i t t l e e f f e c t on t h e t o u g h n e s s o r d u c t i l i t y of h i g h p u r i t y aluminum. Introduction A t t h e p r e s e n t s t a g e of t h e i r development, A1-Li alloys g e n e r a l l y compare u n f a v o r a b l y w i t h c o n v e n t i o n a l aluminum a l l o y s i n terms of t o u g h n e s s a n d d u c t i l i t y a t e q u i v a l e n t s t r e n g t h l e v e l s . For e x a m p l e , A 1 7075 a n d A 1 2024 e x t r u s i o n s made from c o m m e r c i a l i n g o t s times) i m p a c t t o u g h n e s s than have s i g n i f i c a n t l y g r e a t e r (2-3 i d e n t i c a l A 1 8090 a n d A 1 2090 e x t r u s i o n s . T h e r e is e v i d e n c e i n t h e l i t e r a t u r e t h a t t h i s d i f f e r e n c e i n t o u g h n e s s may b e r e l a t e d t o low m e l t i n g p o i n t i m p u r i t i e s s u c h a sodium a n d p o t a s s i u m . Payne a n d Eynon, i n 1957 B r i t i s h P a t e n t 787665, s u g g e s t e d t h a t e m b r i t t l e m e n t o f A1-Li a l l o y s o c c u r r e d i f t h e sodium c o n t e n t w a s o v e r 5 0 ppm. et al, (Ref. 1 ) i n 1976 found a 16% d r o p i n t o u g h n e s s o f Vaynblat, A1-2 Li-0.13 Z r a l l o y s when t h e sodium c o n t e n t was i n c r e a s e d from 3 1 i n 1982 ( R e f . 2) t o 7 6 ppm. More r e c e n t l y , Vasudevan, e t a l , o b s e r v e d l i n e a r d e c r e a s e s i n t o u g h n e s s i n A1-Li a l l o y s c o n t a i n i n g up t o 480 ppm sodium, a n d W e b s t e r ( R e f . 3 ) o b s e r v e d t o u g h n e s s d e c r e a s e s i n A1-Li a l l o y s c o n t a i n i n g up t o 434 ppm sodium a n d 23 ppm p o t a s s i u m . The a d d i t i o n o f sodium a n d p o t a s s i u m p r o m o t e s t h e g r a i n b o u n d a r y 2 ) a n d t h e s e e l e m e n t s have b e e n f r a c t u r e mode i n A1-Li a l l o y s ( R e f . f o u n d by s u r f a c e a n a l y s i s t o s e g r e g a t e t o t h e g r a i n b o u n d a r i e s (Refs. 2, 3 , 4 , , 5 ) . t h e aim o f t h e p r e s e n t work i s t o i d e n t i f y t h e n a t u r e of t h e g r a i n b o u n d a r y s e g r e g a t i o n a n d t h e c h a n g e s l t u n d e r g o e s during aging. Article published online by EDP Sciences and available at http://dx.doi.org/10.1051/jphyscol:1987379 JOURNAL DE PHYSIQUE Experimental Technique Most of t h e a l l o y s e v a l u a t e d i n t h i s work were from a l l o y s c a s t i n t o 1 2 7 mm d i a m e t e r i n g o t s and e x t r u d e d t o f l a t b a r 5 8 x 14 mm. Four a l l o y s w i t h a d d e d Na a n d K were c a s t a s b o t h 127 mm d i a m e t e r i n g o t s , e x t r u d e d t o f l a t b a r and a s 100 mm x 25 mm i n g o t s which were The a l l o y s were m e l t e d u n d e r a n a r g o n h o t r o l l e d t o 6.4 mm p l a t e . atmosphere. Results When l i t h i u m m e t a l i s a d d e d t o a m o l t e n aluminum a l l o y , t h e r e is a n i n c r e a s e i n sodium, p o t a s s i u m and hydrogen l e v e l s i n t h e a l l o y . 22ppm K T h e s e e l e m e n t s a r e p r e s e n t i n t h e l i t h i u m m e t a l ( 5 3 ppm Na, a n d 280 ppm H). A d d i t i o n s of sodium, p o t a s s i u m a n d l i t h i u m g r e a t l y i n c r e a s e t h e hydrogen c o n t e n t o f aluminum a l l o y s . This is n o t s u r p r i s i n g s i n c e hydrogen h a s a h i g h s o l u b i l i t y i n a l l t h r e e a l k a l i metals When t h e d a t a a r e measured a s a t o m i c p e r c e n t a g e s t h e hydrogen c o n t e n t i s e q u a l t o t h e cube r o o t o f t h e sum o f t h e a l k a l i m e t a l s . I n a l l t h e a l l o y s examined t h e r e i s a n e x c e s s of a l k a l i m e t a l s above t h a t r e q u i r e d t o form h y d r i d e s , e v e n b e f o r e t h e a l l o y s a r e d e g a s s e d . S m a l l p a r t i c l e s r i c h i n Na a n d K were o b s e r v e d i n t r a h s m i s s i o n e l e c t r o n m i c r o s c o p y i n a l l t h e a l l o y s examined w i t h a d d e d amounts o f t h e s e elements. The p a r t i c l e s were l e n t i c u l a r i n s h a p e w i t h t h e i r l o n g e s t d i m e n s i o n (0.3-1.7 pm) a l o n g t h e g r a i n boundary. I n many c a s e s t h e r e was a s m a l l p a r t i c l e , r i c h i n Pb w i t h i n of t h e l e n t i c u l a r Na-K p a r t i c l e , s u g g e s t i n g t h a t t h i s was a c t i n g a s a n u c l e a t i n g a g e n t f o r sodium a n d p o t a s s i u m s e g r e g a t i o n . The d i h e d r a l a n g l e o f t h e l e n t i c u l a r Na-K p a r i c l e s a t t h e g r a i n b o u n d a r i e s was found t o be i n t h e r a n g e 100-120 One o f t h e s m a l l e s t (0.3 p m ) s o d i u m - r i c h p a r t i c l e s o b s e r v e d was found a t a g r a i n boundary t r i p l e j u n c t i o n i n a l l o y 2BLKN a n d i s shown i n F i g u r e 1. Inside t h i s p a r t i c l e is a lead-rich particle. The EDX a n a l y s i s from t h i s p a r t i c l e i n d i c a t e s i t i s 81% Na, 1 9 % K. A TEM e x a m i n a t i o n o f a l l o y 2BLK, which c o n t a i n s s l i g h t l y more p o t a s s i u m t h a n 2BLKN, b u t o n l y 6% a s much sodium, shows s i m i l a r g r a i n boundary p a r t i c l e s r i c h i n Na and K which a l s o a p p e a r t o have n u c l e a t e d on l e a d p a r t i c l e s . EDX a n a l y s e s t a k e n from t h e g r a i n b o u n d a r i e s a d j a c e n t t o t h e Na-K p a r t i c l e s show o n l y t h e p r e s e n c e o f aluminum, i n d i c a t i n g t h a t t h e sodium and p o t a s s i u m a r e n o t p r e s e n t a s a u n i f o r m g r a i n boundary f i l m b u t a r e c o n c e n t r a t e d i n isolated particles. Because o f t h e s m a l l volume of e a c h s o d i u m - r i c h particle, a q u a n t i t a t i v e a n a l y s i s of t h e c o m p o s i t i o n c a n n o t b e made by EDX i n t h e STEM. However, t h e Na:K r a t i o c a n be o b t a i n e d , a n d i f t h e a s s u m p t i o n i s made t h a t a p a r t from o c c a s i o n a l n u c l e a t i n g p a r t i c l e s t h e sodiumr i c h p a r t i c l e c o n t a i n s o n l y sodium p l u s p o t a s s i u m , then the c o m p o s i t i o n o f e a c h p a r t i c l e and t h e r e f o r e i t s l i q u i d u s a n d s o l i d u s temperature can be estimated. T h i s h a s been done f o r a l l o y s 2BLK(llppmNa, 23ppm K ) , 2BLKN(476ppm Na, 15ppm K and 2BLKNC( lloppm Na) F i g u r e 2. The c o m p o s i t i o n of e a c h p a r t i c l e i s p l o t t e d o n t h e NaK p h a s e d i a g r a m a t t h e l o w e s t t e m p e r a t u r e a t which a l i q u i d p h a s e c a n I t c a n be s e e n t h a t a e x i s t i n a p a r t i c l e of t h a t composition. l i q u i d p h a s e would b e e x p e c t e d a t room t e m p e r a t u r e i n a l l t h r e e a l l o y s a n d t h a t p o t a s s i u m was i d e n t i f i e d i n t h e g r a i n boundary p a r t i c l e s e v e n when t h e amount was t o o low t o b e d e t e c t e d by b u l k a n a l y s i s (2BLKNC). I n most o f t h e s o d i u m - r i c h p a r t i c l e s o b s e r v e d a f t e r a g i n g a t 394K, s m a l l b u b b l e s were o b s e r v e d moving s l o w l y j u s t i n s i d e t h e p e r i m e t e r of t h e p a r t i c l e i n d i c a t i n g t h a t t h e p h a s e i s i n d e e d l i q u i d <Ref. 6>. 6 . Figure 1. TEM of Na-K particle in grain boundary triple junction of alloy 2BLKN.Dark particle contains Pb. FIG. 2 . Na-K PHASE DIAGRAM SHOWING RELATIVE CONCENTRATIONS OF Na-K ElEASURED BY EDX FROM PHASES OBSFBVED BY 'TI31 WEIGHT PCT. SODlL?l C3-688 JOURNAL DE PHYSIQUE I n o r d e r t o show t h e a l k a l i m e t a l d i s t r i b u t i o n i n a l l o y s w i t h o n l y r e s i d u a l amounts, a more s e n s i t i v e m i c r o - a n a l y t i c a l technique, Rb t h e Cameca I o n Microprobe was used. The d i s t r i b u t i o n o f Na, K , a n d Cs was examined o n b o t h p o l i s h e d s a m p l e s and s a m p l e s f r a c t u r e d i n t e r g r a n u l a r l y a l o n g t h e S-T d i r e c t i o n . The K d i s t r i b u t i o n i n a l5Oum d i a m e t e r c i r c l e on a f r a c t u r e s u r f a c e o f a semi commercial A 1 8091 a l l o y i n t h e peak a g e d c o n d i t i o n is shown i n F i g u r e 3. The Na a n d K d i s t r i b u t i o n s v a r y from p a r t i c l e t o p a r t i c l e b u t t h e l o c a t i o n o f t h e h i g h c o n c e n t r a t i o n s o f e a c h e l e m e n t a r e t h e same a s i n d i c a t e d by t h e TEM work a b o v e . F o r t h e t h r e e l a r g e p a r t i c l e s shown i n F i g u r e 3 t h e a v e r a g e Na a n d K a t o m i c c o n c e n t r a t i o n s were a b o u t e q u a l . The Cs l e v e l s were 24 times l o w e r and t h e Rb l e v e l s were 300 times l o w e r I n t h e c a s e o f t h e K and p e r h a p s a l s o t h e t h a n t h e Na a n d K l e v e l s . Cs a n d Rb t h e r e i s e n r i c h m e n t i n t h e p a r t i c l e s compared t o t h e b u l k composition. FIGURE 3 . PfYFASSIU? DISTRIBUTION ON SEIORT ?EWEVERSE FRACI'LJRE SURFACE OF Al 8091 AUQY EXTRUSION AS SH@,JN BY THE ION .PUCROPROBE. TIE DARK AREAS ARE REGIONS OF HIGH POTASSIW4 C O N ~ R A T I O N S . N a , R b AND C s WE ALSO CONCEJTRA"D I N THE S R I E NZEAS. Na AMD K LFVELS BY BULK ANALYSIS ARE 3 PPM AND 4 0 . 5 PPM RESPECTIVELY. THE NUMBEPS INDICATE TEE REXATIVE POTASSIUq C O N ~ T I O N SI N TI= YATIIIX AND I N THE PAF3ICLE CENTERS. The t e n s i l e and Charpy i m p a c t p r o p e r t i e s of underaged 6 mm A1-Li p l a t e w i t h v a r i o u s a d d i t i o n s ' o f sodium and p o t a s s i u m a r e a s f o l l o w s . A t 295K t h e r e i s a s l i g h t d e c r e a s e i n y i e l d s t r e n g t h w i t h i m p u r i t y c o n t e n t and a s i g n i f i c a n t d e c r e a s e i n d u c t i l i t y and t o u g h n e s s . The h i g h p o t a s s i u m a l l o y s have l o w e r t o u g h n e s s t h a n e x p e c t e d a b o v e 77K, b a s e d o n t h e a s s u m p t i o n t h a t Na a n d K a r e of e q u a l e f f e c t i v e n e s s i n A b e t t e r correlation is obtained i f the reducing toughness. p o t a s s i u m c o n t e n t a l o n e i s assumed t o b e t h a c o n t r o l l i n g f a c t o r . For t h e r e s u l t s a t 295K t h i s i s a l o g i c a l a s s u m p t i o n s i n c e i n a l l t h e a l l o y s , Na which is t h e m a j o r a l k a l i m e t a l i m p u r i t y , i s a s o l i d a t 295K. I n t h e c o m p l e t e a b s e n c e of o t h e r a l k a l i m e t a l s t h e r e f o r e n o e m b r i t t l e m e n t s h o u l d b e o b s e r v e d a t 295K. I n t h i s c a s e t h e amount o f l i q u i d p r e s e n t w i l l b e c o n t r o l l e d e n t i r e l y by t h e s e c o n d m a j o r a l k a l i p o t a s s i u m which when i n t h e p r e s e n c e of sodium m e t a l i m p u r i t y i.e. To b e c o n s i s t e n t t h e f o r m s p h a s e s which a r e l i q u i d below 295K. c h a r p y d a t a f o r 373K s h o u l d b e p l o t t e d a g a i n s t t h e sum o f Na+K s i n c e When t h i s i s d o n e t h i s t e m p e r a t u r e i s a b o v e t h e m e l t i n g p o i n t o f Na. t h e number o f l i n e s on t h e p l o t is r e d u c e d t o two s i n c e t h e 373K d a t a 4). In order t o becomes a n e x t e n s i o n o f t h e 295K d a t a <Fig. FIG.4.EFFECT OF LIQUID IMPURITY LEVELS ,K AT 77K AND Na+K AT 3733 ON CHARPY VALUES OF Al-Li ALLOYS WITH ADDED Na+K. f u l l y e v a l u a t e t h e e f f e c t o f Na a n d K on t h e t o u g h n e s s o f A1-Li a l l o y s , i t i s d e s i r a b l e t o b e a b l e t o e v a l u a t e a n a l l o y where t h e s e e l e m e n t s a r e e x t r e m e l y low. T h i s i s n o t e a s y t o d o by i n g o t metallurgy, however, t h i s c o n d i t i o n c a n b e a p p r o a c h e d i n a l l o y s made by powder m e t a l l u r g y . Two a l l o y s 1 6 1 1 a n d 1614 were a t o m i z e d a t 1200K i n t o -100 mesh [ < I 4 9 p m ] p a r t i c l e s . The h i g h t e m p e r a t u r e a n d t h e s m a l l p a r t i c l e s i z e would b e e x p e c t e d t o e n a b l e a l m o s t a l l t h e sodium and potassium t o evaporate. Specimens were aged a t t e m p e r a t u r e s u p t o 533K a n d t e s t e d a t room t e m p e r a t u r e a n d 77K. The temperature dependence of toughness f o r t h e s e a l l o y s was q u i t e d i f f e r e n t from i n g o t m e t a l l u r g y a l l o y s c o n t a i n i n g h i g h e r Na a n d K. The powder a l l o y s showed a d e c r e a s e i n t o u g h n e s s a t 77K u n d e r a l l a g i n g c o n d i t i o n s < F i g . 5>. Discussion The a b o v e r e s u l t s show t h a t t h e a d d i t i o n o f l i t h i u m t o aluminum K and H. r e s u l t s i n a n i n c r e a s e i n t h e u n d e r s i r a b l e i m p u r i t i e s Na, A l l t h r e e of t h e s e e l e m e n t s a r e c o n c e n t r a t e d i n t h e g r a i n b o u n d a r i e s reduce t h e <Ref. 3 > , a n d t h e K a n d t o a lesser e x t e n t t h e Na, t o u g h n e s s o f A1-Li a l l o y s a t t e m p e r a t u r e s a b o v e a p p r o x i m a t e l y 200K. The t e m p e r a t u r e d e p e n d e n c e o f i m p a c t t o u q h n e s s a n d d u c t i l i t y , o f JOURNAL DE PHYSIQUE FIG.5 TOUGHNESS AS A FUNCTION OF AGING TEMPERATURE FOR POWDER METALLURGY EXTRUSIONS 1611 AND 1612 TESTED AT 295K and 77K. a l l o y s w i t h a d d e d Na and K , and a l l o y s w i t h o n l y r e s i d u a l amounts of these elements, d i f f e r o n l y i n t h e m a g n i t u d e o f t h e e f f e c t <Ref. 3 ) . I t h a s b e e n shown t h a t t h e s e e l e m e n t s o c c u r a s i s o l a t e d g r a i n boundary p a r t i c l e s r a t h e r t h a n c o n t i n u o u s g r a i n boundary f i l m s . T h e s e l i q u i d p h a s e s c a n a c t a s g r a i n boundary c r a c k s , w h i c h c a u s e extensive local deformation i n the grain boundary region. I m p u r i t y p a r t i c l e s c o n t a i n i n g o n l y Na a n d K a r e l i q u i d down t o 260K a c c o r d i n g t o t h e phase diagram. The a l l o y s i n v e s t i g a t e d i n t h i s work show a n i n c r e a s e i n t o u g h n e s s down t o a t l e a s t 200K. This suggest t h a t o t h e r i m p u r i t y e l e m e n t s , s u c h a s t h e Cs a n d Rb o b s e r v e d a b o v e i n t h e i o n m i c r o p r o b e , a r e a s s o c i a t e d w i t h Na a n d K. In the ternary s y s t e m , Na-K-Cs, a l i q u i d p h a s e c a n e x i s t down t o 195K a n d t h e s o l i d u s is l o w e r e d f u r t h e r i n t h e p r e s e n c e of m e r c u r y . I n most A1-Li a l l o y s , a c o n t i n u o u s i n c r e a s e o f t o u g h n e s s would b e e x p e c t e d between t h e f r e e z i n g p o i n t o f Na a n d t h e Na-K-Cs eutectic. T h i s would p r o d u c e a marked s i m i l a r i t y t o t h e a c t u a l t o u g h n e s s - t e m p e r a t u r e 3,5>. The t o u g h n e s s o f A1-Li r e l a t i o n s h i p s o b s e r v e d <Refs. a l l o y s i n c r e a s e s markedly a s t h e t e s t temperature is d e c r e a s e d , w h i l e t h e t o u g h n e s s of c o n v e n t i o n a l h i g h s t r e n g t h aluminum a l l o y s d e c r e a s e s a t low t e s t t e m p e r a t u r e s . The r e s u l t o f t h i s i s t h a t t h e s t r e n g t h t o u g h n e s s c o m b i n a t i o n of A1-Li a l l o y s a t c r y o g e n i c t e m p e r a t u r e s i s e q u a l t o , o r i n many c a s e s s u p e r i o r t o , t h a t o f c o n v e n t i o n a l aluminum alloys. T h i s a p p e a r s t o c r e a t e a problem f o r a l t e r n a t e t h e o r i e s f o r t h e e m b r i t t l e m e n t o f A1-Li a l l o y s s u c h a s s t r a i n l o c a l i z a t i o n d u e t o S t r a i n localization theories do not predict t h e o r d e r e d A 1 Li phase. a n i n c r e a s e i n toughness a t cryogenic temperatures n o r a n absence of embrittlement a t these temperatures. Conclusions 1. The a d d i t i o n of u p t o 4 7 6 ppm Na a n d 23 ppm K t o A1-Li a l l o y s reduces t h e i r impact toughness and d u c t i l i t y b u t h a s l i t t l e i n f l u e n c e on strength. 2. Na a n d K r e d u c e t o u g h n e s s a n d d u c t i l i t y by f o r m i n g d i s c r e t e l e n t i c u l a r g r a i n b o u n d a r y p a r t i c l e s w h i c h a r e l i q u i d a t room temperature. These l i q u i d p h a s e s promote i n t e r g r a n u l a r f a i l u r e . The s o l i d i f i c a t i o n o f t h e l i q u i d p h a s e s a t t e m p e r a t u r e s down t o a b o u t 200K r e s u l t s i n a n i n c r e a s e i n t o u g h n e s s a n d d u c t i l i t y . Acknowledgements. The a u t h o r would l i k e t o t h a n k t h e f o l l o w i n g p e r s o n n e l o f K a i s e r Aluminum & C h e m i c a l C o r p o r a t i o n l s C e n t e r f o r Technology i n P l e a s a n t o n , C a l i f o r n i a ; D.A. Nguyen f o r o u t s t a n d i n g t r a n s m i s s i o n m i c r o s c o p y , R. H i n t z e f o r t h e development of improved Wentz, R.C. a n a l y t i c a l t e c h n i q u e s f o r a l k a l i m e t a l s a n d a l s o D. D i c k i n s o n a n d K.S. Dayton. I n a d d i t i o n t h e e x p e r t i s e of C h a r l e s E v a n s a n d Ron F l e m i n g o f C h a r l e s E v a n s a n d A s s o c i a t e s i n Redwood C i t y , C a l i f o r n i a was i n v a l u a b l e when u s i n g t h e i o n m i c r o p r o b e . 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