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Equal Channel Angular Pressing (ECAP): Part One :: Total Materia Article
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Equal Channel Angular Pressing (ECAP): Part One
ECAP is one of te most commonly employed severe plastic deformation process to drive nano or ultrafine grained microstructure at low homologous temperatures.
ECAP is most suitable for materials used in industrial scale application, te process works by introducing a large shear strain by repeated extrusion steps.
Among te different procedures in use for te production of nanostructured materials, only severe plastic deformation (SPD) processes exhibit a potential for producing relatively large samples suitable for industrial applications. Severe plastic deformation is metal forming processes in which an ultra-large plastic strain is introduced into a bulk metal in order to create nano- or ultrafine- grained structure at low homologous temperatures (typically below 0.3 of te melting temperature).
In order to obtain te smallest microstructural sizes plastic strains of more than 600 to 800% are necessary. Such high degrees of plastic deformation are possible because one sample can be subjected several times to SPD in order to accumulate te total amount of plastic strain.
Equal Channel Angular Pressing (ECAP) is one of te most employed methods of Severe Plastic Deformation (SPD); it can be applied to a variety of metals and alloys in order to obtain ultrafine grains and good mechanical and physical properties. Te recent literature shows intense and growing interest in some fundamental aspects of SPD techniques, viz., te generation of ultrafine grains and te mechanisms underlying te high levels of strength observed. Aluminum and its alloys, Cu and Ti are te most employed materials in SPD-ECAP studies, with Ti being seriously considered for orthopedic implants.
Te current trend in research and development of Ti alloys for biomedical applications is te development of alloys with low elastic modulus, free of toxic and allergic elements such as Al and V, while maintaining te already good mechanical properties of Ti-6Al-4V.
For producing large size stock that is suitable for industrial application, te equal channel angular pressing (ECAP) process is most suitable. This process involves introducing large shear strain in te work piece by pushing it through a die that consists of two channels with te same cross sectional shape that meet at an angle to each other. Since te cross-sections of te two channels are te same, te extruded product can be re-inserted into te entrance channel and pushed again through te die. Repeated extrusion through te ECAP die accumulates sufficient strain to breakdown te microstructure and produce ultra-fine grain size.
Te principle of ECAP is illustrated schematically in Figure 1. For te die shown in Figure 1, te internal channel is bent through an abrupt angle, Φ, and there is an additional angle, Ψ, which represents te outer arc of curvature where te two channels intersect. Te sample, in te form of a rod or bar, is machined to fit within channel and te die is placed in some form of fuss so that te sample can be pressed through te die using a plunger.
Te nature of te imposed deformation is simple shear which occurs as te billet passes through te die. Te retention of te same cross-sectional area when processing by ECAP, despite te introduction of very large strains, is te important characteristic of SPD processing and it is this characteristic which distinguishes this type of processing from conventional metal-working operations such as rolling, extrusion and drawing. Since te cross-sectional area remains unchanged, te same billet may be pressed repetitively to attain exceptionally high strain.
Figure 1: Principle of ECAP
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