In situ X-ray observation of semi-solid deformation and failure in Al–Cu alloys

Semi-solid deformation has been directly observed in an Al–12 wt.% Cu alloy through the combination of real-time synchrotron X-ray radiography and a bespoke high-temperature tensile tester over a range of fraction solid from 0.35 to 0.98. During deformation at low and moderate fraction solids, the X-ray radiographs indicate that there is significant feeding of interdendritic liquid in the region of strain localization prior to crack formation. Furthermore, the measured load required to initiate localized tensile deformation was found to be similar over the range of fraction solid 0.35 to 0.66. At higher fraction solids, the radiographic observations are consistent with classical hot tearing behaviour: limited liquid flow due to low permeability; void nucleation and coalescence; and final failure. Based on these results, a three-stage mechanism for semi-solid failure is proposed which includes the effects of liquid flow and micro-neck formation.