An Evaluation of the Impact Effect on the Surface Microstructure and Its Induced Temperature Changes during Ultrasonic-Assisted Micro-Forging

In the field of ultrasonic-assisted micro-forming, in addition to acoustic softening, impact effects also play a significant role, especially in terms of influencing the deformation behavior of surfaces, such as by generating more deformation on surface asperity. In this study, to understand the mechanisms involved in the effect of an impact, ultrasonic-assisted micro-forging tests were conducted on commercially pure copper, pure aluminum, and pure titanium. A method that can measure the increment in the temperature during ultrasonic vibration was developed. As a result, changes in the surface temperature of the material under the impact effect and acoustic softening were measured. It is indicated that, during ultrasonic vibration, the heat generated through acoustic softening is very limited and the main heat increase occurs after the impact effect. Once the impact effect occurs, the surface temperature increases with increasing amplitude. Nevertheless, for materials with different crystal structures, the influences of the impact effect are also different. The surfaces of copper and aluminum soften, creating more surface deformation, but the exact opposite effect is seen on a titanium surface. Observing the evolution of the microstructure on the material surface with EBSD demonstrates that the impact effect on FCC materials can reach deeper below the surface in terms of temperature diffusion compared to titanium. Meanwhile, the impact effect in the case of titanium causes the regeneration of twinning, which is reduced under the influence of the acoustic softening effect, consequently resulting in strain hardening.