1. Introduction
Copper alloys are useful candidates for elevated temperatures and high heat flux (100 MW m
2) applications, such as heat sinks, rocket engine combustion chambers, nozzle liners, and reusable launch vehicle (RLV) technologies, where a high thermal conductivity, good elevated temperature strength, resistance to creep, and low cycle fatigue are needed [
1,
2,
3,
4]. Several such Cu alloys, including Cu-Ag-Zr [
1,
5], Cu-Zr (AMZIRC) [
1,
4], Cu-Al
2O
3 (GlidCop) [
1,
6], Cu-Cr-Nb (GRCop) [
7,
8], and Cu-Cr-Zr [
9,
10], have been developed, which exhibit high thermal and electrical conductivities and strength at elevated temperatures. For example, the alloy AMZIRC has an ultimate tensile strength (UTS) of 500 MPa at room temperature, and its strength decreases to 260 MPa at 500 °C and then drops significantly below 50 MPa when above 600 °C [
1]. The decrease in strength at elevated temperatures is mostly due to the recrystallization, grain growth, and growth of second-phase particles or precipitates. The Cr-rich GRCop-84, developed for high heat flux applications, shows good elevated temperature strength, which stems from the precipitation hardening of Cr
2Nb precipitates. These precipitates reduce grain growth by pinning grain boundaries at elevated temperatures [
1]. Additionally, copper-based metal matrix composites find applications in the electronics and automotive industries due to their excellent wear resistance, corrosion resistance, mechanical properties, and electrical properties. They are also promising materials in future fusion reactors. This is due to their high thermal conductivity and good mechanical properties.
However, one of the critical drawbacks of these composites is the rapid loss of plastic strength at elevated temperatures close to the melting point, owing to rapid recrystallization and grain growth. Controlling recrystallization and grain growth is, therefore, very important to retain strength at elevated temperatures. We report here a heavily cold-worked Cu-Al
2O
3 composite that did not recrystallize up to a temperature of 0.85T
m of Cu. It has been reported in GlidCop (Cu-Al
2O
3) [
1,
6,
10] that the recrystallization process of the Cu matrix can be inhibited at relatively elevated temperatures with a dispersion of a small amount of Al
2O
3 precipitates (~1%). A number of boundaries might not be effectively pinned by such a small volume fraction of Al
2O
3 particles as the Zener pinning depends on the fraction and the size of precipitates. One could achieve a higher level of Zener pinning if the particle size is significantly small, even with the lower volume fraction (1%) of the precipitate. The objective of this research is to investigate fine-scale microstructure using transmission electron microscopy (TEM) and to revisit the mechanism of mitigation of recrystallization of internally oxidized cold-rolled Cu at relatively elevated temperatures. The Cu-Al
2O
3 composite was manufactured through the internal oxidation process of dilute Cu-0.15 wt.% Al alloy.
3. Results
The in situ internal oxidation process of Cu-Al alloy results in the formation of Al
2O
3 within grains as well as at grain boundaries. In this composite, the estimated volume fraction of Al
2O
3 is around 1% [
10,
11,
12]. Note that the Al and oxygen content in the composite is 0.15 and 0.17 wt.%, respectively. The Al atoms in the Cu matrix become oxidized to form Al
2O
3 due to the reaction, 4(Cu-Al) + 3O
2 = 4Cu + 2Al
2O
3. After the internal oxidation process, the powders were consolidated at elevated temperatures and cold rolled to form plates. The bright-field TEM image (see
Figure 1a) of the as-received cold-rolled plate of GlidCop Al-15, obtained along the rolling direction, shows elongated columnar grains as a result of cold working. The average width of the columnar grains is ~100 nm, measured from a number of TEM images obtained from different areas of the sample. We utilized TEM images for this measurement as the XRD peak broadening is influenced by the higher dislocation density. In addition, we observe alumina particles at grain boundaries (see the inset of
Figure 1a). These elongated Cu grains are highly oriented with a very strong 220 reflection of Cu, while the 111 peak is very weak (see
Figure 1b). It is known that cold working on Cu produces a brass-type texture, which can lead to a strong 220-type reflection. Cu is known to form brass-type texture upon heavy deformation (cold working) with very strong 220 [
13,
14]. The major slip system in copper is {111} <110>. During the rolling process, the majority of {220} planes tend to orient towards the rolling plane. As the {111} <110> slip system becomes active, it aligns the {110} planes parallel to the plane containing the rolling directions [
14]. To minimize the strain contrast as a result of cold rolling, we use multibeam imaging to clearly show the elongated grains and oxide precipitates within grains and grain boundaries. In
Figure 2a, the multibeam image shows the elongated grains with fine dispersion oxide particles within a grain. These oxide particles pin the dislocations (see
Figure 2b) and increase the yield strength by the Orowan mechanism.
To study the nature of the aluminum oxide particle formed during the oxidation process, we performed HRTEM imaging. These studies show that the aluminum oxide particles are not distributed uniformly in the matrix, and the particle size within the matrix grain ranges from 10 to 20 nm (see
Figure 3a). The HRTEM image (see
Figure 3b), close to the 110 zone, shows gamma alumina (γ-Al
2O
3) with {111} lattice spacing of ≈4.6 Å, consistent with the {111} lattice spacing of known γ-Al
2O
3 with lattice parameter a ≈7.97 Å. The corresponding FFT is shown in
Figure 3c. One can observe that it is cube-on-cube orientated with the matrix. In some cases, we observe that the orientation of γ-Al
2O
3 has deviated from the cube-on-cube orientation (see
Figure 3d). At grain boundaries, however, we observe coarse alumina particles, mostly faceted and parallel to the boundary. In some cases, the size (length) is in the range of 200 to 300 nm (see
Figure 4a). A number of grain boundaries were observed to be free of these oxide particles.
Figure 4b is an HRTEM image obtained from the area indicated as rectangular box “A” in
Figure 4a, showing the interface and a portion of the faceted Al
2O
3 particle. The corresponding FFT shows it is a γ-Al
2O
3 particle close to the zone 112 at the grain boundary.
The cold-worked samples were heated to 900 °C and then cooled to room temperature. TEM observations show that the grains (G-1 through G-8) were still columnar (see
Figure 5a) even after exposure to elevated temperatures, suggesting the recrystallization did not occur at high homologous temperatures. We examined different areas of the sample and did not observe nucleation of equiaxed grains and dislocation cells or subcells within the elongated grains (see inset of
Figure 5a). Note that the recrystallization process usually produces equiaxed grains that are substantially free of dislocations. Instead, due to thermal exposure, we observe a change in grain orientation as evidenced by the increase in the intensity of the 111 reflection at the expense of the intensity of the 220 reflection (see
Figure 5b). In fact, the intensity ratio of 220/111 decreases from 17.5 to 1.33 (see
Figure 1b and
Figure 5b for comparison) after annealing. In addition, we observe limited grain coarsening in some areas using TEM. We, in fact, examined a number of areas (around 10 to 15 instances) and observed localized grain coarsening.
Figure 6a is a multibeam image showing the coarsening of grains A and B at the expense of grain C. At certain locations, the width of the grain has increased significantly to 400 nm from the average grain width (
Figure 6a) of 100 nm. This indicates that the grain coarsening is related to the growth of 111-oriented grains at the expense of some of the 220-oriented grains. Note that the intensity of the 220 peak is still greater than that of the 111 peak after annealing. However, the grain coarsening does not induce any recrystallization in this composite. Upon heating, XRD shows that the intensity of the 111 peak increases at the expense of the 220 peak (see
Figure 1b and
Figure 5b). Note the significant change in the intensity ratio of 220/111 upon heating to elevated temperature as compared to the intensity ratio of 220/111 in the as-received condition. The increase in intensity of the 111 peak is mostly related to the growth of 111-oriented grains, which grow at the expense of the 220-oriented grains upon heating. This reduces the overall energy of the system. Note that we have a small number of grains with 111 orientations in the as-received condition. As we have not observed any recrystallization, the reorientation of grains upon heating is the result of the localized growth of the 111-oriented grains. In addition, in some areas, we observed that the grain boundaries were pinned by Al
2O
3 particles (see
Figure 6b,c). Note that the volume fraction of Al
2O3 particles is just ~1%, and a significant fraction of grain boundaries are not pinned by these particles.
Most of the dislocation is still pinned even after heating (see inset of
Figure 5a), although some amount of dislocation redistribution has been expected to take place after heating to a high homologous temperature. In fact, we observe the low-angle grain boundary formation in some areas as a result of recovery or redistribution of dislocations.
Figure 7a is a low-magnification bright-field image showing the distribution of dislocations and a low-angle grain boundary. The dislocations are shown by arrows. A higher magnification image of the low-angle boundary, along with the oxide particles, obtained from the square area indicated in
Figure 7a, is shown in
Figure 7b.
Figure 8 is the HRTEM image of this low-angle boundary, showing the periodic dislocations and a small tilt of the 111 plane across the boundary, demonstrating some amount of recovery taking place during annealing. The angle of the low-angle grain boundary is approximately 10
0.
Additionally, we observe annealing twins in elongated grains oriented close to the 110 zones in this composite. Annealing twinning in pure Cu usually occurs during the growth of the recrystallized grains in the deformed matrix. Note, here, that no recrystallization has been observed in the present case in the deformed Cu-Al
2O
3 matrix.
Figure 9a is a low-magnification image showing twins in an elongated grain, running through the grain and ending at the other side of the grain boundary. Steps associated with twins at either side of grain boundaries are observed (see
Figure 9b). The high-resolution TEM (HRTEM) image (see
Figure 9c), close to the 110 zone, shows twins consisting of bundles of stacking faults in 111 lattice planes in the copper matrix. The fault packets are shown. In some cases, these faults are initiated and ended within the grain (see
Figure 9c). The fast Fourier transform (FFT) from the stacking fault bundle shows twin spots (see the inset) and streaks along the 111 direction.
The internal oxidation process can also result in the formation of copper oxide particles, a small fraction of dissolved oxygen, and copper–aluminum–oxygen clusters in the matrix. Such a fine dispersion of oxide particles and clusters increases the hardness and elastic modulus of the composite [
11] as compared to commercially pure Cu. In fact, we observed a very fine dispersion of Cu-oxide particles within the elongated grains of Cu before and after the annealing treatment using HRTEM.
Figure 10a shows the dispersion of cubic Cu
2O particles in the as-received condition, as shown by arrows. The corresponding FFT (see the inset) shows Cu
2O reflections in a cube-on-cube orientation with the Cu matrix. The d-spacing, 0.246 nm, conforms to 111 Cu
2O. We extracted an inverse FFT (IFFT) image (see
Figure 10b) from the 111 Cu
2O spots to show these oxide particles indicated by circles. The particle size ranges from 2 to 4 nm in diameter. One could estimate the amount of Cu
2O in the matrix from a number of HRTEM-IFFT images, which turned out to be ~15%. The chemical composition can, in principle, be obtained by energy dispersive spectroscopy (EDS) or EDS mapping. However, the size and spacing of the Cu-oxide particles are extremely small, which could result in significant spurious counts from the Cu matrix. In addition, the EDS information will not be quantitative as they are oxide particles. Thus, lattice imaging would be the efficient method to obtain the stoichiometry of these nanosized Cu-oxide particles. We looked at a number of regions/grains to make sure that we had enough statistics. Upon exposure to elevated temperature, we observed that these Cu
2O particles did not grow significantly (see
Figure 11a,b). They retain their original size and spacing as these oxide particles originally form at high temperatures during the internal oxidation process of Cu-Al powders.
4. Discussion
In the Cu-Al
2O
3 composite material under investigation, the recrystallization process does not take place even at temperatures > 0.8T
m, as evidenced by the multibeam imaging (see
Figure 5 and
Figure 6). In pure Cu [
15], on the other hand, the recrystallization process readily occurs in the deformed matrix, and annealing twins form mostly during the growth stage after recrystallization. It has also been reported that these annealing twins play an important role in the nucleation of recrystallized grains. It is known that fine-scale precipitates will slow down the recrystallization process. For example, in the Al-Sc system [
16], the fine-scale Al
3Sc precipitates increase the Zener pinning effect at elevated temperatures. However, at higher temperatures, these precipitates were observed to grow, the Zener effect was minimized/reduced, and recrystallization occurred. In our system, we find that the nanocrystalline semicoherent Cu
2O precipitates within grains in addition to Al
2O
3 particles (see
Figure 10). These particles do not grow significantly even after annealing close to the melting temperature of Cu (see
Figure 11). These Cu
2O precipitates exert significantly higher Zener drag force as compared to Al
2O
3 particles.
As is well known, the driving force for recrystallization and grain growth in cold-worked metal is mostly the stored deformation energy in the form of dislocations. The driving force is ΔP = 0.5 ρµb2, where ρ is the density of dislocations and µb2 is the energy of dislocations. The µ is the shear modulus, and “b” is the Burgers vector. The as-received sample is heavily deformed (the deformation level is 80%), suggesting the driving force for recrystallization is rather strong. The presence of strain concentration (hot spot) due to rolling would increase the tendency to recrystallize. As we have not observed any recrystallization, it suggests the strain concentration might be less. When considering the density of dislocation as 1015 m−2 for heavily cold-worked alloy and the dislocation energy as 10−8 Jm−1, the estimated driving force is 10 MPa. However, the driving force, 2γ/r, for grain boundary migration due to grain boundary energy would be two to three orders of magnitude smaller, as the radius, r, of the elongated grain (longer side) would be much higher. Thus, the recrystallization would be mostly driven by the stored energy. Although the segregation of oxygen at grain boundaries can alter the grain boundary energy, the driving force contribution for grain boundary migration would be much smaller as compared to the stored energy.
We have observed limited grain growth (thickening) and no recrystallization for the sample heated to elevated temperatures (900 °C). Some of the elongated grains grow by increasing their width to some extent and increase the population of 111-oriented grains, as the intensity of 111 increases at the expense of 220. The 111-oriented grains will have lower energy compared to the 220-oriented grains. The grain boundary also experiences a drag effect due to the presence of Al
2O
3 particles within the grains and at grain boundaries. Drag develops as a result of the attractive force between the particle and grain boundary, as it reduces the part of the grain boundary upon contact with the particle, which is known as the Zener force. The Zener force is proportional to the number of particles at grain boundaries or the volume fraction of particles in the system. The reduction of grain boundary free energy per particle, ΔG, and the corresponding Zener force, Z
f, are given below [
17]:
where r is the radius of the particle, and γ is the interfacial energy of the precipitate matrix interface. Note, here, that the volume fraction of Al
2O
3 particles is ~1%, suggesting the effect due to the Zener force would be small. Therefore, the contribution of the Zener effect on recrystallization behavior would be small. In a number of cases, we observed the portion of the grain boundary is free of Al
2O
3 particles.
Thus, it is reasonable to discuss another alternative mechanism in this system. TEM results show, in addition to Al
2O
3 particles, the presence of nanocrystalline (2 to 5 nm in diameter) semicoherent Cu
2O particles within the matrix grains (see
Figure 10 and
Figure 11) in as-received and annealed conditions, respectively. In addition to Al
2O
3 particles, one could expect copper oxide, a small fraction of oxygen (the solubility of oxygen in Cu at the eutectic temperature is 0.008 wt.%), to be in the matrix during the internal oxidation process. Such a fine dispersion of oxide particles increases strength and could inhibit the recrystallization of the copper matrix at temperatures close to the melting point of copper. These Cu
2O particles are oriented in a cube-on-cube relation within the matrix grain. The grain boundary migration will result in an orientation change in the particle. Consequently, the interfacial energy change is given by [
17]
where γ
1 and γ
2 are the interfacial free energies of semicoherent Cu
2O particles in the growing and vanishing grains, respectively. The experimentally observed volume fraction of Cu
2O particles using HRTEM is ~15%, which is considerably higher than the volume fraction of Al
2O
3 particles, suggesting substantial Zener drag due to Cu
2O particles. The Zener drag depends on the fraction and the size of precipitates. A higher level of Zener pinning as the Cu
2O particle size is significantly smaller in the range of 2 to 4 nm in diameter. The recrystallization nucleation, i.e., the nucleation of defect-free regions, requires the presence of supercritical nuclei of different orientations. The nucleation of deformed Cu grain recrystallization does not occur by thermal fluctuations. Usually, a subgrain or cell structure greater than the critical size present in the deformed system can act as a possible nucleation center. The critical size is given by [
17]
The estimated critical size, rc, is around 100 nm, considering the grain boundary energy to be 1.0 Jm−2 and ΔP to be 10 MPa. Usually, a subgrain or cell structure greater than the critical size present in the deformed system can act as a possible nucleation center. TEM results show no obvious dislocation cell formation after annealing, suggesting recrystallization nucleation events may not occur. In addition, as the Cu2O particles are cube-on-cube oriented in the deformed matrix, the formation and the growth of the recrystallized grains of different orientations would be energetically expansive and produce higher Zener drag, according to Equation (3), due to the difference in the interfacial free energies of semicoherent of Cu2O particles in the growing and vanishing grains.
Additionally, the migration of the grain boundary of the deformed grain is required for the formation of viable recrystallization nuclei and annealing twins. In this case, the grain boundary migration is restricted due to the Zener drag exerted by the second-phase particles. Here, we estimate the Zener drag due to the presence of the nanocrystalline Cu
2O and Al
2O
3 particles. The particles in contact with the grain boundary per 1 m
2 of a boundary are n = 2rN, where r is the radius of the particle and N is the number of particles per unit volume [
17]. The volume fraction of the particle, V
P, is (4/3) πr
3N. Considering the experimentally estimated volume fraction of Cu
2O particles to be 15%, the number of particles, n, in contact with the boundary is 16 × 10
15 per m
2 of the boundary. The maximum pinning Zener drag force [
17] is Z
F = (3/2) V
pγ
p/r, where γ
p is the particle/matrix interfacial energy. The estimated maximum pinning force exerted by the Cu
2O particles is 5 × 10
7 Jm
−3, considering the γ
p to be 0.5 Jm
−2. Similarly, the estimated maximum Zener force exerted by Al
2O
3 particles is 7.5 × 10
4 Jm
−3, indicating the pinning force exerted by Cu
2O particles is three orders of magnitude greater than that of Al
2O
3 particles. This limits the migration of the boundary consistent with the experimental observations of the limited grain growth and the fault bundle formation instead of annealing twins. Note that the volume fraction of Al
2O
3 particles in the composite is ~1%, and the particle size is considerably larger (see
Figure 4) as compared to Cu
2O.
Twinning is a mode of plastic deformation in addition to slip. Two types of twins are known as deformation twins and annealing twins. Annealing twins are more likely to form when grain boundaries migrate as pointed out by Pande et al. [
18,
19]. In 1963, Dash and Brown [
20] made the first observations on the early stages of annealing twins. They also showed, for the first time, that twin nuclei consist of stacking fault packets having complicated morphology. Their explanation for the formation of the observed features lacked mechanistic details. A microscopic model based on nucleation of partial dislocations for the formation of annealing twins in fcc crystals was proposed by Mahajan et al. [
21]. In their paper, it is argued that Shockley partial loops nucleate on consecutive {111} planes on a moving boundary by growth accidents occurring on migrating {111} steps associated with the boundary. The higher the velocity of the boundary, the higher the twin density. In the present case, we, too, observe early-stage twin formation as the twins are not fully developed due to limited grain boundary migration. Here, the twins are not sharp and are associated with bundles of stacking faults (see
Figure 9). Usually, twinning proceeds from a moving high-angle grain boundary. As stated earlier, the driving force, which is the stored energy, is high in this case as it is heavily deformed. Although the presence of twinning has been reported to be associated with the low driving force for recrystallization [
13], in this case, the fault bundles are obviously not due to the low driving force. Our results suggest a bundle of faults on 111 lattice planes formed due to the passage of partials as a result of boundary migration. In this case, the fault bundles did not collapse to form sharp twins or twin chains due to limited grain boundary migration.