Effect of Radial-Shear Rolling on the Structure and Hardening of an Al–8%Zn–3.3%Mg–0.8%Ca–1.1%Fe Alloy Manufactured by Electromagnetic Casting

Aluminum alloys are one of the most common structural materials. To improve the mechanical properties, an alloy of the Al–Zn–Mg–Ca–Fe system was proposed. In this alloy, when Fe and Ca are added, compact particles of the Al(10)CaFe(2) compound are formed, which significantly reduces the negative effect of Fe on the mechanical properties. Because of the high solidification rate (about 600 K/s) during cylindrical ingot (~33 mm) production, the electromagnetic casting method (ECM) makes it possible to obtain a highly dispersed structure in the cast state. The size of the dendritic cell is ~7 μm, while the entire amount of Fe is bound into eutectic inclusions of the Al(10)CaFe(2) phase with an average size of less than 3 μm. In this study, the effect of radial shear rolling (RSR) on the formation of the structure and hardening of the Al–8%Zn–3.3%Mg–0.8%Ca–1.1%Fe alloy obtained by EMC was studied. Computer simulation of the RSR process made it possible to analyze the temperature and stress–strain state of the alloy and to select the optimal rolling modes. It was shown that the flow features during RSR and the severe shear strains near the surface of the rod (10 mm) provided a refining and decrease in the size of the initial Fe-containing particles.