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High pressure compressive reverse shearing: A new severe plastic deformation process.

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Title: High pressure compressive reverse shearing: A new severe plastic deformation process.
Authors: Kumar, Govind1 (AUTHOR), Huilgol, Prashant2 (AUTHOR), Toth, Laszlo S.1,3,4 (AUTHOR) laszlo.toth@univ-lorraine.fr, Suwas, Satyam5 (AUTHOR), Kailas, Satish V2 (AUTHOR)
Source: Materials & Design. Sep2025, Vol. 257, pN.PAG-N.PAG. 1p.
Subjects: Metal fabrication, Shear (Mechanics), Industrial applications, Strain rate, Material plasticity, Mechanical behavior of materials
Abstract: The process is readily up-scalable for industrial-level applications. [Display omitted] • A new single step SPD process for producing UFG metallic sheets is presented. • In HPCRS, compression is combined with oscillating shear to introduce extremely large strain in the metal. • Control strength-ductility combinations by varying the oscillation frequency. • Can process materials with all crystal structures including powders. • High metal forming speed, metallic sheets obtained in less than 15 seconds. Severe plastic deformation (SPD) processing improve mechanical and physical properties but are suffering from inherent limitations, including restricted sample size, low processing speed, and limited strain per cycle, which hinder their industrial adoption. To overcome these challenges, we introduce a novel SPD process termed High Pressure Compressive Reverse Shearing (HPCRS). This technique imposes a large accumulated shear strain in a reciprocating manner, coupled with a uniaxial compressive load, enabling single-step deformation of bulk and powder-consolidated metals. The process has been successfully applied to materials with diverse crystal structures: commercially pure Al, OFHC Cu, IF steel, Zn, and pre-compacted Al and Mg powders. In CP Al, for an 83 % thickness reduction, the estimated equivalent strain, shear strain, and compressive strain were approximately 42, 73, and 1.8, respectively. Ultra-fine grains obtained with a pronounced shear texture. Mechanical testing showed a threefold increase in strength at low processing frequency (0.1 Hz), and good ductility (20–30 %) for all frequencies, accompanied by a decrease in strength (230 MPa to 100 MPa), attributed to strain rate-induced thermal effects. Notably, at 20 Hz, deformation was completed within 15 s. Therefore, HPCRS can be readily applied for industrial-scale metal forming. [ABSTRACT FROM AUTHOR]
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Database: Engineering Source
Description
Abstract:The process is readily up-scalable for industrial-level applications. [Display omitted] • A new single step SPD process for producing UFG metallic sheets is presented. • In HPCRS, compression is combined with oscillating shear to introduce extremely large strain in the metal. • Control strength-ductility combinations by varying the oscillation frequency. • Can process materials with all crystal structures including powders. • High metal forming speed, metallic sheets obtained in less than 15 seconds. Severe plastic deformation (SPD) processing improve mechanical and physical properties but are suffering from inherent limitations, including restricted sample size, low processing speed, and limited strain per cycle, which hinder their industrial adoption. To overcome these challenges, we introduce a novel SPD process termed High Pressure Compressive Reverse Shearing (HPCRS). This technique imposes a large accumulated shear strain in a reciprocating manner, coupled with a uniaxial compressive load, enabling single-step deformation of bulk and powder-consolidated metals. The process has been successfully applied to materials with diverse crystal structures: commercially pure Al, OFHC Cu, IF steel, Zn, and pre-compacted Al and Mg powders. In CP Al, for an 83 % thickness reduction, the estimated equivalent strain, shear strain, and compressive strain were approximately 42, 73, and 1.8, respectively. Ultra-fine grains obtained with a pronounced shear texture. Mechanical testing showed a threefold increase in strength at low processing frequency (0.1 Hz), and good ductility (20–30 %) for all frequencies, accompanied by a decrease in strength (230 MPa to 100 MPa), attributed to strain rate-induced thermal effects. Notably, at 20 Hz, deformation was completed within 15 s. Therefore, HPCRS can be readily applied for industrial-scale metal forming. [ABSTRACT FROM AUTHOR]
ISSN:02641275
DOI:10.1016/j.matdes.2025.114450