Of Of: Effects Ultrasound Deformation Characteristics Metals
Of Of: Effects Ultrasound Deformation Characteristics Metals
Of Of: Effects Ultrasound Deformation Characteristics Metals
1 MARCH, 1966
Abstract-Experimental evidence is presented for several effects hardening [ 3 ] . I n the first of these, acoust,ic irradiation
that ultrasonic stress waves have on physical properties of metals. reduces theapparentstaticstress necessaryforplastic
Amplitudes up to -lo9 dyn/cm2 at frequencies between 15 kc/s and
1 Mc/s are applied. Interpretations of the phenomena and aspects
deformation; it is usuallyobserved during application
of possible applications in industrial forming processes are given. of ultrasound. Ilardening, on the other hand, is a phe-
nomenon which, in general, is observed and invest'igated
IXTKODUCTION after ultrasonic irradiation.
In earlier experiments [I], [4],metal crystals were ir-
HT;: RIIXH--lSICAL characteristics of metals are radiated in a Polanyi [-l] tensile apparatus; tlle specimens
largely determined by lattice imperfections; there- were mounted in pin vises of the tester and positioned so
fore, a complete understanding of the properties of that a quartz crystal transmit,ted sound wtlves through
metals can only he achieved by deterlninillg the behavior a liquid 1):Ltll t,o tlle t,lle spccinums. Since cavitation in the
of latticedefects under variousphysicalcircumstances. liquid makes thistecllnique i1npr:xtical at intensities
The environment,produred hy ultrasonicirradiation above 10 IV/c1n2, sanlples' are 1 1 0 1 ~[S]fastened directly
of metals for lattice defects is of corlsidertlble interest'. t o a trulsdac:c!r horn (a Branson Sonic I'ower velocity
Intense ultrasonic stress waves force dislocations to oscil- transformer [(;l).
latewithamplitudes comparallle to distancesbetween Figure I shows stress-strain c~~rv(:s wllich \vere obtained
theirequilibriumpositionswhen 110 ult,rasorlic fieldis
from tensile tests of higIl-purit,y alun1ilum single crystals.
applied. In turn, pronounced influences on metal plasticity The dnsllcd curve? indicate tlle plastic behavior of metal
occur, some of which shall he hiefly described inthis crystalsundercontinuousultrasonicirr:~diation a t 20
paper. kc/s and a t various power levels; tlle solid curves rep-
The experirnent:ll details of application of ultrasound resent the plasticity of aluminuln as it depends o n tem-
are nom modemtely w-1~ll-established.The interpretation peratlure. S o t e t,llat the shear stress can be reduced hy :ts
of the elfcots oI)scrredj however, is incompletebecause mucl1 as 100 percent, [:l, down to "zero stress",when
dislocation theoryandthetheory on mechanical wave u1tr:w)und of -50 IYi'cm2 is applied.
propagation are ~ ~ atlequate
o t t o describe interactions of Soft metals like zinc single crystals can be brought to
high-amplitude ultrasonic strcss waves wit11 dislomtions. zero stress by about 25 ITT/cInzof ultrasound, while room
Heseardl on the effects of ultrasound therefore aids inthe temperat,urc (ISOC) tests on stailllcss steel :md beryllium
:icpisition of fur1d:mmltalknowledge aboutmetal plas- show that zero stress can be p r o d u c d in sucll metals by
ticity. about 80 to 100 W / / ( ! m 2 ; acousticsofteningllas been
The results of our investigations may also be looked a t observed in all other metals that were tested, including
from the viewpoint of industrial application, keeping in cadmium, iron, titanium, and tungsten [.';l
mind the possible application of ultrasound t o large-scale Acousticsoftening takes placeirnmediately when a
forming processcs andthe strengt,llening of materials metal is subjected to ultrasonia irradiation; thus, if one
through ultrasonic treatment. appliesultrasoundintermittentlyduring a tensil test,
This paper presents the underlying effects; but it, does the static stress will drop abruptly whenever the ultra-
not discuss details, since it is intended to give an overall sound is switcahed on.
pict,ure, starting wit11 a description of some prototype Intense ultrasound and heat seem to havesimilar effects
experiments and their results, and then pointing to tlle on the apparent shear stress, as shown in E'ig. 1, but one
difficulties that co~lfrontu s when we at,tempt t o describe significant difference is that it takes about 10" eV/cm3
t8he effects ohserved. Certainexperiments,designed to of thermal energy d e r d y t o produce a zero stress in
evaluate our concepts and first, interpretations, are now aluminum when110 u1tr:lsound is applied, while ultrasound
yielding a more complete picture which this paper follows alone may redl1ce tlle apparent shear st,ress t o zero a t an
step by step. acoustic energy density of only 1 0 ' ~eVjcm3.
BASICPHESOJlES.4 The difference in the energies involvedhas been ascribed
to the preferred absorption of acoustic energy a t disloca-
Therearetwo pronounc~ed"nonlinear"effects of ul- tions [>l. Acoustic: energy is assumed to be absorbed only
trasound on metals: acoustic softening [l], [ 2 ] and acoustic
1 Intenbit,iesare c.al(*rllatedfrom the mensnred electrical power
Manuscript received 1)cc~ernl)er3, 1'364; reviied >larch 26, 1965. input :tssurning that the trarlsduccr is $10 percent efficient and that
The author is withthe Research I)epartment, IT. S. X'sval all the poner passes uniformly throllgh the a r w o f :L 1.35-cm diameter
Ordnance Test Station, China Lake, Calif. horn tip.
1
2 IEEE TRANSACTIONS ON SONICS AND ULTRASOKICS MARCH
200‘C
400’C
600°C
I I I I I I
0 20 60 100
ELONGATION, S.
4 00 l
295OK
Fig. 3. Pure slip (left) and kinking (right) of zinc single crystals by
,
E
E
m
g 240
v)
v)
320
n
The amount of acoustic hardening which can possibly
a
W be achieved is limited by the fact that application of
1
v)
eo ultrasound much more than 25 W/cm2 may cause plastic
deformation or kinking [S], as illustrated in Fig. 3, and
may even fracture metal crystals.
1.0 I .5 The fact that intenseultrasoundmayhardenmetal
GLIDE S T R A I N crystals is another phenomenon which dist,inguishes ul-
Fig. 2. Acoustic hardening in zinc crystals trasonic andheattreatment of metals.Application of
(glide rate U = 6 X 10-6 S-’). intense ultrasound causes the hardening described; heat,
however, causes permanent softening of the metal.
a t those regions in the met’al lattice which are known t o
carryout t’hemechanisms of plasticdeformation (e.g., THE STRESSCRITERION
dislocations and grain boundaries), since little attenuation From the viewpoint of dislocation theory, the resolved
occurs in defect-free crystal regions [ 7 ] .Heat, on the other shear stress 7, i.e., the stress that is needed t o produce
hand, is distributedrather homogeneously amongall continuous plastic flow [4], is the &ress required for sub-
the atoms of the crystalincludingthose which do not stantial dislocation migration in the slip plane [g]. When
participateinthe mecllanisms of plasticdeformation. ultrasound reduces the apparent’ shear stress of a cryst>nl
Thus,activation of plasticdeformationbyheat is less to zero, theorypredictsthatthe acoustic field must
efficient than activation by uItrasound. supply a stress X = 7.
Figure 2 illustrates the second of the two fundamentd The acoustic(tensional)stress X produced by an ul-
phenornenn of ultrasound, the acoustic hardening w-hich trasonic wave traveling through a solid may be calculated
shows up after one has applied ultrasound of sufficiently from [lo]
high-st,ress amplitudes. At point a ultrasound, a t a power
level intensity of about 5 1Y//cm2 (relatively low), is
applied. We observe the reduction in the apparent shear
x = Epwc = p u c = 4; IY
stress mentioned above; if the strain rate is constant and where is the particle displacement, p is the density, o t’he
the acoustic field is turned off, the stress returns t o it’s angular frequency, c the sound velocity-, U the particle
original curve at point a’ without any aftereffects of t,he velocity, I the intensity, and I.’ is Young’s modulus. I n
acoustic treatment. Fig. 4 the acoustic stress X is plotted as a function of
If, however,ultrasound a t a Ievcl above 1 5 lT/cm2 ultrasonic intensity, and the critical resolved shear stress
isapplied,ithas a residual effect which is obserrcd (or “yield point” [4]) T~ is marked for each material. S o t e
as hardening after the acoustic irradiation is stopped; in that all of our experiments have been carried out in the
Fig. 2 this treatment and its effect are marked by points lower left-hand quadrant of this diagram a t intensities
b and b‘ where the hardening shows up as a higher stress below 100 ’IT’jcm2or a t correspondingacousticstresses
1966 DEFORMATIONLANCENECKER:
METALS OFCHARACTERISTICS 3
IO" r
I I I I
1=160dB 10 IO2 I 03 I0 4 105
90,000
INTENSITY (watt/crn2)
L O
600
Sound l-
f 500
1,200r
g
0
400
” 300
z
% 200
4
100
0 ‘ I I I I I I
2ooL
0 0.1 0.2 0.3 0.4 0.5
TIME, (SEC)
05
0 I I I I I I I I I I I
I.o 1.5 2.0 1.0 1.5 2.0 Fig. 9. Damping corlstant, vs. time from the beginning of ultrasonic
D, cm irradiation in SAE 1019 steel.
(a) (b)
Fig. 6. Temperature profile of standard tensile samples a t several
increments Of time after the beginning o f ultrasonic irradiation.
(a) Profile at 35 watts. ( b ) Profile a t 80 watts power input.
inferred, and to adequatelyexplain the acoustic activation Onlyspeculations areleftto describeplausibly the
of dislocations. Below is a n outline of present attempts to experimentalfacts of acousticsoftening.However, the
describe the loss of acoustic energya t dislocation sites. apparent quantitative disagreementbetween the observed
or calculated acoustic stresses X and those expected from
ACOUSTIC ACTIVATION OF DISLOCATIONS dislocation theory (X should equal T ) can be resolved by a
Theory provides several mechanisms by which metals refined explanation of the experimental results that takes
absorb energy from sound waves (see the review articles into account temperature changes caused by the sound
byMasonandEntwistle [7], [24]). Probablythemost waves. I n particular, it is suggested that since dislocations
important effects are those of thermoelastic energy con- absorb the acoustic energy, localized heating takes place
version [ 2 5 ] , those due to the motion of dislocations [26], in the regions around dislocations when ultrasonic stress
[27], and energytransformation effect dueto inclastic waves propagate through the crystal. These heated areas
scattering [ B ] , [ B ] . of dislocations are then “weak spots” in the met,al and
Thermoelasticeffectsplay animportant role a t fre- so aremovable a t much lower resolved shearstresses
quencies in the megacycle range [3O]. They are, however, (or static yield stresses) than those required a t t h e meas-
negligible a t frequencies of -20 kc/s. ured specimen t’emperature.It then follows that our work-
Three mechanisms of absorptionassociated wit,h dis- ing hypothesis is in qualitative and quantitative agree-
location motion are resonance, relaxation, and hysteresis. ment with theory. The stress criterion may thus be written
The natural frequency of oscillation yo of dislocation in the form
lines is known to be in the order of10’ c/s, and since the
input frequency was -20 kc/s resonance effects can be
x ‘v T’, (5)
disregarded. If the relaxation mechanism were responsible where T’ is the apparent static shear stress required for
for significant absorption, there would be a spectrum of substantial plastic
deformation a ta n elevated
tem-
characteristic relaxation frequences v R = voe-Q’LT, where perature.
Q = activation energy (barrier height), k is Boltzmann’s
constant, and T is the absolute t’emperature. By varying ULTRASONIC FORMING OF METALS
T , it is possible t o sweep through a wide range of relaxa- Acoustic softening has the possibility of aiding forming
tion frequencies v R while applying ultrasonic irradiation processes provided that the coupling of acoustic energy t o
at a constant frequency V,,. Whenever v R = v,, a n anoma- the forming apparatus is such that sound is applied prin-
lous decrease in the shear stress should be observed;how- cipally to the region of deformation [37].
ever, none was observed in the temperature range used Working inthe kilocycle range,Aeroprojects, Inc.,
PI, ~311. WestChester,Pa. [38], performed the firstactual ul-
Hysteresis does not appear to be a suitable mechanism trasonic extrusion of metals. They reported as much as
for absorption of large amounts of acoustic energy; how- 15-percent reduction in the forces necessary t o draw or
ever, it may account for a background loss [ll]. extrude metal wires or tubes. A more efficient approach
A quite remarkable amount of energy can be extracted t o a n industrical use of effect of intenseultrasound on
from the appliedsound field by the mechanism of jog metals wasachieved at thislaboratory [39]. A wire-
formation(vacancyorinterstitial) a t dislocation inter- drawingdevice which isacoustically matchedwith a
sections. IIomever,it is difficult t o explain how dislocations Branson Sonic Power S-75 transducer is shown in Fig. 11.
mightmove and intersect each other, if it is true that The whole device including the electromechanical trans-
x < T. ducer has a hole along its length axis, thus allowing con-
Energy conversion by inelastic scattering is clue to t,he tinuous drawing of wire, tubes, or other extruded forms;
difference in orientation between adjacent grains within the die is located at the displacementantinode of the
a polycrystalline material [29]. If inelastic scattering were transducer horn.
t o be of importance in our experiment,s, one would expect I n another application, copper shdls were ironed and
R significant difference between the effects upon polycrys- deep-drawn [37]. A formingtoolwasdesigned t o con-
talline material (with small grains and a large number of centrate intense ultrasound a t those points where most
boundaries) and upon single crystals (with no boundaries). of the deformation t,akes place. When copper cups were
No such difference was observed [lI]. ironed t o approximatelytwice the originallength, the
Theories of isotropic scattering by randomly distributed forming load was 220 Ib, measured byan Instron compres-
scatterers [32] do not simplify the problem; and ultrasonic sion cell. In thesame process, but with intense ultrasound
attenuationby phonon-phononorphonon-electron [33] of about 70 W/cm2 a t 20 kc/s, the forming load was re-
interactions does not become appreciable under our ex- duced to about TO lb. The implication is that ultrasonic
periment,al conditions. It may be interesting t o consider a softening may speed up forming processes by eliminating
quantum mechanical effect [34]-[36] that would permit some intermediate steps in the common operations.
didocations to penetrate barriers a t stresses lower than Lip curling of copper cups under the influence of ul-
the shear stress, but to the best of our knowledge only trasound is illustrat’ed in Fig. 12. The forming forces re-
partial theories, valid a t Eow temperatures, are presented quired for curling in the presence of ultrasound were re-
in the literature on this particular subject. duced by more than 50 percent.
1966 LANGENECKER: DEFORMATION CHARACTERISTICS OF METALS 7
RESONATORS [METAL)
manent changes appear in the properties of metah. On
MOUNTING FLANGE the other hand, irradiation a t high power levelscauses
m/
/ absorption of sufficient acousticenergy a t dislocation
sites to activate dislocations and to free them from their
pinnedequilibriumpositions; the amplitudes of oscil-
lations of dislocations increaseuntil theyexceed the normal
distances between equilibrium positions. When there is a
superposition of acousticstresses andinternal stresses
GLUED WITH‘EPOX?RESIN $TEP HORN DIE AT‘THE produced by lattice imperfections, dislocations are forced
ANTINODAL t o move in apreferreddirection, thereby changing the
POINT
Fig. 11. Ultrasonic wire-drawing device.
internalstructure;inother words, materialproperties
undergo permanent changes. Such processes may be as-
sociated with the development of heat depending upon
amplitude and duration of uItrasonic irradiation.
Acoustic heating, however, offers a new means of zone
melting. It also provides a simple check on the coupling
between ultrasonic source and specimen; acoustic energy
must be transmitted efficiently t o cause heating. Finally,
acoustic heating and high-temperature fracture of metals
are stjrongevidence thattherearedrastic changes in
Young’s modulus during application of ultrasound. This
conclusion which was arrived a t earlier in I l l ] is supported
byindependent evidence reportedin [40],thus making
impossible a statementin [42] that ultrasoundhasno
effect on the elasticitmy modulus.
Acoustic heating can be turned on and off rapidly, which
,‘ . ,. offers a new quenching technique. We prefer to prevent
1 _ _
, -
, ” .1 . ...OI ” I