Abstract Grain boundary character distribution (GBCD) of cold-rolled Pb-Ca-Sn-Al alloy during recovery and recrystallization was investigated by means of electron back scatter diffraction (EBSD).The results indicate straight ∑3 boundaries of over 60% (length fraction of total boundaries, the same as follows) are introduced in the alloy during recovery. Such boundaries are not distributed in the network of general high angle boundaries (HABs) and the GBCD are not optimized. Conversely, in the recrystallization, apart from ∑3 boundaries of over 65% , a fairly amount of ∑9 and ∑27 coincidence site lattice (CSL) boundaries are appeared. ∑9 and ∑27 boundaries along with a great deal of curved ∑3 boundaries are located in the network of HABs and the GBCD are optimized. Further discussion pointed out the straight ∑3 boundaries formed in recovery are <111>60°coherent twin boundaries, they are stable and immobile. While, the ∑3 boundaries developed in recrystallization comprised of not only coherent twin boundaries but also most of incoherent ones. The migration of incoherent ∑3 boundaries as well as the interaction between them result in the formation of ∑9,∑27 and other ∑3n (n is a positive integer) boundaries, and it is the root of GBCD optimization.
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