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The present authors have proposed insitu composites in which cold working was applied to the cutting chip mixture of dissimilar materials. The composites have exhibited superior strength together with ultrafine grain structure. In this study, such composite materials are produced by combining 6061 aluminum alloy and IF steel chips. Microstructural evolution processes are visualized by means of the microtomography as well as the TEM observation. It has been clarified that ultrafine grains with a large fraction of high angle boundaries are obtained due to the effects of severe plastic deformation during cutting. Grain size of the matrix aluminum alloy is reduced to about 220 nm by applying swaging strain of only 1.9. It should be noted that the significant strain hardening of the chips occurs during initial deformation stage where strain applied by swaging seems to be consumed mostly for consolidation. The chips gradually change their orientation in the material at this stage. It can be inferred that the rapid development of ultrafine structure in the matrix is also attributed to gradual change in deformation axis thereby realizing effective multiaxial deformation. Overall, the utilization of chips is identified as a highly effective way of grain refining compared to the other uniand multiaxial deformation processes.

Microstructural Evolution in Heavily Deformed In-Situ Composites Produced from Cutting-Chip Mixtures of Dissimilar Metals