Effect of Cryo-Rolling on the Microstructural Evolution and Mechanical Properties of Ti-6Al-4V Alloy

Ti-6Al-4V is valued for its strength-to-weight ratio in engineering applications. Cryo-rolling at sub-zero temperatures enhances strength and hardness through grain refinement and dislocation build-up. The present study investigates the role of cryo-rolling on the microstructural characteristics and mechanical properties of the alloy, which undergoes various degrees of deformation followed by heating at 900 °C for selected samples. Microstructural analysis reveals grain elongation, sub-grain formation, deformation bands, and dislocation densification with increasing thickness reduction. Twinning dominates deformation at low strain, while dislocation slips take over at high strain because of the decrease in grain size, which makes the formation of new twins progressively more challenging. No metastable phase appears during cryo-rolling or heat treatment, as confirmed by X-ray diffraction. Cryo-rolled samples exhibit about 45% and 29% reduction in grain size and crystallite size, and 160% intensification in dislocation density. This leads to rises of 19%, 23%, and 10% in yield strength, tensile strength, and hardness, respectively, while ductility remains nearly constant across all cryo-rolled conditions. Cryo-rolling inhibits dynamic recovery and recrystallisation, so strengthening mainly results from grain refinement and dislocation accumulation. These findings suggest that cryo-rolling can improve the strength and hardness of Ti-6Al-4V, while maintaining ductility and providing new processing insights.