High Temperature Deformation Behavior and Processing Maps of AZ31 Alloy Deformed in Tension versus Compression

The effect of the applied state-of-stress on the processing maps depicting the mechanisms for hot working of hot extruded Mg-3Al-1Zn alloy has been evaluated. Flow stresses at various temperatures in the range 300 – 500 °C and strain rates in the range 0.0003 – 1 s-1 have been measured by deforming in compression and in tension. Processing maps have been developed from the respective flow stress data at a strain of 0.1. The maps are essentially similar irrespective of the mode of deformation – compression or tension, and exhibited two domains in the temperature and strain rate ranges: (1) 375 – 500 °C and 0.0003 – 0.01 s-1, and (2) 450 – 500 °C and 0.1 – 1 s-1. On the basis of slower strain rates, high tensile ductility, and the apparent activation energy (152 kJ/mole closer to that for self-diffusion), Domain #1 is interpreted in terms of the occurrence of climb controlled dynamic recrystallization. In Domain #2, which occurs at higher strain rates and has an apparent activation energy near to 165 kJ/mole, dynamic recrystallization occurs that involves second order pyramidal slip {11-22} <11-2-3> and recovery by cross-slip of screw dislocations. The state-of-stress imposed on the specimen (compression or tension) does not have any significant effect on the processing maps or the kinetics of hot deformation.

A Finite Element Study of Thermo-Mechanical Fields and Their Relation to Friction Conditions in Al1050 Ring Compression Tests

The most accepted method for determining friction conditions in metal forming is the ring compression test (RCT). At high temperatures, extraction of the friction coefficient, μ, commonly requires numerical analysis due to the coupling between the mechanical and thermal fields. In the current study, compression tests of cylindrical specimens and RCT experiments were conducted on commercially pure aluminium (Al1050) at several temperatures, loading rates, and lubrication conditions. The experiments were used in conjunction with a coupled thermo-mechanical finite element analysis to study the dependence of the friction coefficient on those parameters. It is demonstrated that due to the coupling between friction conditions and material flow stress, both μ and flow stress data should be determined from the cylinder and ring specimens simultaneously and not subsequently. The computed friction conditions are validated using a novel method based on identification of the plastic flow neutral radius. It is shown that, due to heat loss mechanisms, the experimental system preparation stage must be incorporated in the computational analysis. The study also addresses the limitation of the RCT in the presence of high friction conditions. The computational models are finally used to examine the thermo-mechanical fields, which develop during the different processes, with an emphasis on the effect of friction conditions, which were then correlated to the resulting microstructure in the RCTs.

Development of Processing Map for Superplastic Deformation of Ti-6Al-4V Alloy

A processing map plays a major role in indicating safe and failure regions of a process conducted in a hot working regime. It also shows the response of a material, by indicating changes in the microstructural evolution through temperature. In the present study, a processing map has been developed depending on the flow stress data of Ti-6Al-4V alloy sheet in a strain rate range of 10−2 /s to 10−4 /s and over a temperature range of 700°C to 900°C in order to identify the presence of superplasticity region. The flow stress data have been acquired on the basis of temperature, strain and strain rate by conducting hot uniaxial tensile tests. Based on this, a power dissipation map is obtained to show the percentage of efficiency, as it is directly related to the amount of internal entropy produced. In addition, an instability map is also obtained, as it identifies the flow instability that are to be avoided during hot working process. Finally, a processing map has been established by overlaying instability map on efficiency map. The results clearly reveal that the superplastic deformation occurs within a temperature range of 750°C to 900°C at a strain rate of 10−4 /s, without any flow instability in this region.

Evaluation of Lubricants for Stamping of Al 5182-O Aluminum Sheet Using Cup Drawing Test

Lubricants are necessary to avoid adhesion, galling, and scratching in aluminum stamping processes. In this study, various lubricants, including dry lubes and wet lubes, were evaluated using cup drawing test (CDT) for stamping of Al 5182-O aluminum sheets. The effects of surface texturing, with electro-discharge texturing (EDT) and mill finish (MF), on the friction behavior were also investigated. Furthermore, the methodology to evaluate the performance of lubricants was established based on (a) maximum applicable blank holder force (BHF) and (b) draw-in length in flange or flange perimeter of formed cups. Finite element (FE) simulations were carried out to determine the coefficient of friction (CoF) at tool–workpiece interface during deep drawing under different lubrication conditions. Flow stress data of Al 5182-O material were obtained using viscous pressure bulge (VPB) and tensile tests. In this study, it was confirmed that, in forming Al 5182-O, dry film lubricants have better lubricity than wet lubricants. A better lubrication condition was found with EDT surface texture.

Hot Deformation and Processing Maps of 7005 Aluminum Alloy

The deformation behavior of 7005 alloy was studied by hot compression tests. The processing map was constructed by superimposing the instability map over the power dissipation map at a strain of 0.7 using the corrected flow stress data to eliminate the effect of friction. Microstructural examination was performed for validation. It can be found that the flow stresses increase with the decrease of deformation temperature or the increase of strain rate. At the relatively high strain rates, the material exhibits flow instability manifesting as adiabatic shear bands or flow localization. A large volume of coarse precipitations distributing in the grain boundaries in one of the peak efficiency domains: 275–325 °C/0.0005–0.001 s−1, which may result in inter-granular corrosion and spalling layer, should be avoided in the final deformed alloy. The optimum hot working domain is the temperature range of 400–450 °C and strain rate range of 0.0005–0.005 s−1, at which DRX is identified.

Processing Map of Mg-13Al-3Ca-3Zn-1Nd-0.2Mn Magnesium Alloy

Compression tests of Mg-13Al-3Ca-3Zn-1Nd-0.2Mn Magnesium alloy as-extruded had been performed in the compression temperature range from 200°C to 400°C and the strain rate range from 0.001 s−1 to 10 s−1 and the flow stress data obtained from the tests were used to develop the power dissipation map, instability map and processing map. The most unsuitable zones in the power dissipation map including 200°C - 315°C and 0.01s-1- 0.1s-1 zone, 315°C - 400°C and 0.001s-1- 0.01s-1zone and 340°C - 360°C and 0.32 s-1- 0.56 s-1zone. The most unsuitable zones in the instability map are 310°C - 400°C, 0.001s-1to 0.56 s-1zone and 330°C - 400°C, 1s-1to 10 s-1zone. The most suitable temperature range is 330°C - 400°C and most optimal strain rate ranges are 1 s-1- 10 s-1and 0.001s-1- 0.56 s-1.

Flow Behavior and Processing Map of Mg-4Al-3Ca-1.5Zn-1Nd-0.2Mn Magnesium Alloy

Compression tests of Mg-4Al-3Ca-1.5Zn-1Nd-0.2Mn Magnesium alloy as-extruded had been performed in the compression temperature range from 200°C to 350°C and the strain rate range from 0.001 s1to 1 s1and the flow stress data obtained from the tests were used to develop the power dissipation map, instability map and processing map. The optimum parameters for hot working of the alloy had been determined. According to the processing maps, the most optimal temperature range is 280°C to 350°C and most optimal strain rate range is 0.001 S-1to 1 S-1.

Characterization of the Hot Deformation Behavior of a Al-Si Alloy Using Processing Maps

The compression tests of solution treatment ZL109 alloy have been performed in the compression temperature range from 250°C to 450°C and the strain rate range from 0.0005s-1to 0.5s-1. A processing map has been developed on the basis of flow stress data obtained as a function of temperature and strain rate, which revealed two domains of hot working for the alloy: one is situated at temperature between 270°C and 340°C with strain rate between 0.05s-1and 0.5s-1, the other is situated at the temperature between 380°C and 450°C with strain rate between 0.0005s-1and 0.004s-1. Combining with the processing map, the optimum parameters of hot working for ZL109 alloy are that 300°C/0.5s-1and 450°C/0.0005s-1, respectively. Microstructure observations indicated that DRX occurred in both these domains. The instable zones, i. e., adiabatic shear bands formation, wedge cracking, were also identified in the processing map and microstructural examination was performed for validation.