Crack growth in ultrafine-grained AA6063 produced by equal-channel angular pressing

Crack growth behaviour of ultrafine-grained AA6063, processed by equal-channel angular pressing (ECAP) via route E at room temperature, was evaluated with special emphasis on the effect of grain size distribution and work hardening. A bimodal, two times ECAPed condition and a monomodal ultrafine-grained condition after eight ECAP passes are compared with the coarse grained peak aged material. Depending on their microstructure, the ECAPed materials show significantly lower fatigue threshold values (ΔK_th) and higher crack growth rates (da/dN) than their coarse grained counterparts. Micrographs of the crack propagation surfaces reveal the reduced grain size as major key to increased crack growth rates of the ECAPed material, as it influences roughness-induced crack closure and crack deflections. Furthermore, the effects of other features, such as ductility, work hardening capability and grain boundary characteristics, are discussed.