As received sample is rolled well in 10 passes with 5% reduction in each pass while its breaking after solution heat treatment like brittle material in one or two passes.
It is advisable to process the heat treatable aluminium alloys as soon as possible after solution treatment (with in ~4 hrs) to complete the process before the precipitation hardening starts.
If you are following this, then please check the material for any inclusions which might have caused brittleness in alloy.
There could be several reasons why an aluminum alloy breaks after solution heat treatment during rolling in one or two passes, while it rolls well in the as-received condition. Here are a few possible explanations:
Over-aging: If the aluminum alloy is over-aged, it can become brittle and prone to cracking. During solution heat treatment, the alloy is heated to a high temperature and then rapidly quenched to achieve a homogeneous microstructure. If the heat treatment is not properly controlled or the quench rate is too slow, the alloy may become over-aged, leading to cracking during subsequent processing.
Work hardening: Rolling is a form of cold working, which can cause the aluminum alloy to become work hardened. If the alloy is already work hardened before rolling, it can become more prone to cracking. Solution heat treatment followed by rapid quenching is intended to soften the alloy, but if the quench is not effective or the cooling rate is too slow, the alloy may retain some of its work-hardened properties, making it more susceptible to cracking during subsequent processing.
Surface defects: If the aluminum alloy has surface defects, such as scratches, cracks, or pits, these can act as stress concentrators during rolling, leading to cracking. Solution heat treatment may reveal or exacerbate these defects, making the alloy more prone to cracking during rolling.
Improper rolling conditions: Rolling must be performed under the correct conditions, such as the right temperature, speed, and pressure. If the rolling conditions are not properly controlled, the aluminum alloy may become overheated or over-pressured, leading to cracking.
To determine the exact cause of the cracking, it would be necessary to perform a detailed analysis of the alloy and the processing conditions.