Improvements in the microstructure and fatigue behavior of pure copper using equal channel angular extrusion

In this study, annealed pure copper was extruded using equal channel angular extrusion (ECAE) for a maximum of eight passes. The fatigue resistance of extruded specimens was evaluated for different passes and applied stresses using fatigue tests, fractography, and metallography. The mechanical properties of the extruded material were obtained at a tensile test velocity of 0.5 mm/min. It was found that the maximum increase in strength occurred after the 2nd pass. The total increase in ultimate strength after eight passes was 94%. The results of fatigue tests indicated that a significant improvement in fatigue life occurred after the 2nd pass. In subsequent passes, the fatigue life continued to improve but at a considerably lower rate. The improved fatigue life was dependent on the number of passes and applied stresses. For low stresses (or high-cycle fatigue), a maximum increase in fatigue resistance of approximately 500% was observed for the extruded material after eight passes, whereas a maximum fatigue resistance of 5000% was obtained for high-applied stresses (or low-cycle fatigue). Optical microscopic examinations revealed grain refinements in the range of 32 to 4 μm. A maximum increase in impact energy absorption of 100% was achieved after eight passes. Consistent results were obtained from fractography and metallography examinations of the extruded material during fatigue tests.