The potential of ultrafine grained light metals is reviewed. The fundamental metallurgical processes, microstructures developed and properties obtained are first considered. Methods employing severe plastic deformation to achieve ultrafine structures are described and the obstacles to their industrial scale exploitation discussed. Recent advances include the incremental equal channel angular pressing (I-ECAP) process developed at the University of Strathclyde. Ultrafine grained materials are currently utilised in sputtering targets and high value medical devices, but large potential markets exist in the leisure and sports sectors, and in the longer term for aerospace and automotive applications.Users of metals often treat them as continuous bodies to be formed or machined and often forget that metals are made of grains: discrete domains of different lattice orientation. The polycrystalline nature of metals is too frequently viewed as a 'hidden feature', decided during metallurgical processing and thus remaining beyond the influence of most users converting metals into products. However, this perception may be changed by a new technology, which is much closer to the reach of traditional metals converters. Known as severe plastic deformation (SPD), it is capable of refining the coarse grained (CG) structure of metals and alloys to an average grain size of less than 1 µm. SPD is a top-down method of producing bulk ultrafine grained (UFG) metals, contrary to the bottom-up methods based on consolidation of nanoparticles. UFG metals possess a range of interesting properties, which make them attractive for advanced applications.
Grain refinement by severe plastic deformationThe mechanism of grain refinement by SPD is still under investigation. However, the general view is that refinement results from the non-uniform distribution of dislocations, which tend to form cell structures within the original coarse grains. Another opinion emphasises the role of shear bands (thin bands of localised shear deformation) where different bands cross each other to create a pattern resembling a chessboard. The distance between shear bands is very small, which leads to the creation of dislocation cells having sub-micrometre dimensions. The dislocation cells, which do not initially have very different crystallographic orientation from their neighbours, are referred to as subgrains. Only when their misorientation angle exceeds 15°, are they treated as distinct grains. To achieve this state, severe plastic deformation is required. The average grain size of the UFG metals produced depends on the SPD parameters (strain, temperature, pressure) and on the material used; for pure metals, grains tend to be larger, e.g. 0.6 µm for aluminium 1070 (Fig. 1), whereas alloys respond better, e.g. 0.2 µm for Al 5083 under similar processing conditions. Sometimes, the average grain size achieved by SPD can reach the nanometre level (<0.1 µm) as in the case of nickel subjected to SPD at high pressure. The nanostructuring mechanism described is universal f...