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Application of Advanced Metal-Forming Technology in Light-Weight Alloys

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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Metals and Alloys".

Deadline for manuscript submissions: closed (20 May 2023) | Viewed by 22376

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Prof. Dr. Shihong Zhang

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Guest Editor

Institute of Metal Research, Chinese Academy of Sciences, Shenyang, China
Interests: high-performance metallic materials; advanced sheet forming methods; precision fabrication of tube; plasticity theory; constitutive modeling; microstructure modeling; deformation mechanisms under high strain rate; impact hydroforming; fracture modeling

Dr. Shuaifeng Chen

E-Mail Website
Guest Editor

Institute of Metal Research, Chinese Academy of Sciences, Shenyang, China
Interests: light-weight metallic alloys; microstructure and texture optimization; material modeling; multi-scale modeling; crystal plasticity simulation; recrystallization mechanism; fracture modeling
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Dear Colleague,

Light-weight alloys have important roles in modern industries, enabling sustainable development in an energy-saving and environmentally friendly way. Especially for aerospace, automotive industry, or civil engineering applications, the use of light-weight alloys, including aluminum alloy, magnesium alloy, and titanium alloy, has achieved a certain degree of success. In recent years, advanced light-weight alloys have been developed to satisfy the increasing demands for mechanical behavior and in-service performance (fatigue, creep and damping, etc.). Generally, the high performance of these advanced light-weight alloys is realized via the control of grain structure and phases (or precipitations) of various fractions, shapes, and sizes. Additionally, components with complex profiles are always needed to fulfill the designated structure function.

In fact, the combination of advanced light-weight alloys and complex-shaped components is of great significance and high efficiency for further weight reduction and performance improvement, whereas inferior ductility and poor formability are usually found in advanced light-weight alloys due to a constrained relationship between strength and ductility. Meanwhile, the complex shape of components further increases the difficulty in the forming process. Thus, the development and application of advanced metal-forming technology in light-weight alloys has become an essential research topic.

The current Special Issue aims to compile the recent developments in the field of advanced metal-forming technology and its application to light-weight alloys. The potential papers cover reviews of recent progress, understanding of microstructure and texture evolution during advanced processing and forming methods, the development of new forming technology, and the application of advanced forming technology to light-weight alloys.

Prof. Dr. Shihong Zhang
Dr. Shuaifeng Chen
Guest Editors

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Keywords

light-weight alloys
processing method
forming technology
complex-shaped components
thin-walled structures
microstructure and texture evolution
multi-scale modeling
constitutive model
crystal plasticity simulation
experiment characterization
formability and fracture

Published Papers (12 papers)

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Research

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20 pages, 6330 KiB

Open AccessArticle

Modelling the Flow Behaviour of Al Alloy Sheets at Elevated Temperatures Using a Modified Zerilli–Armstrong Model and Phenomenological-Based Constitutive Models

by Ali Abd El-Aty, Yong Xu, Yong Hou, Shi-Hong Zhang, Sangyul Ha, Liangliang Xia, Bandar Alzahrani, Alamry Ali, Mohamed M. Z. Ahmed and Abdallah Shokry

Materials 2024, 17(7), 1584; https://doi.org/10.3390/ma17071584 - 29 Mar 2024

Viewed by 732

Abstract

The flow behaviour of AA2060 Al alloy under warm/hot deformation conditions is complicated because of its dependency on strain rates (

\dot{ε}

), strain (

ε

), and deformation modes. Thus, it is crucial to reveal and predict the flow behaviours of [...] Read more.

The flow behaviour of AA2060 Al alloy under warm/hot deformation conditions is complicated because of its dependency on strain rates (

\dot{ε}

), strain (

ε

), and deformation modes. Thus, it is crucial to reveal and predict the flow behaviours of this alloy at a wide range of temperatures (

T)

and

\dot{ε}

using different constitutive models. Firstly, the isothermal tensile tests were carried out via a Gleeble-3800 thermomechanical simulator at a

T

range of 100, 200, 300, 400, and 500 °C and

\dot{ε}

range of 0.01, 0.1, 1, and 10 s⁻¹ to reveal the warm/hot flow behaviours of AA2060 alloy sheet. Consequently, three phenomenological-based constitutive models (L-MJC, S1-MJC, S2-MJC) and a modified Zerilli–Armstrong (MZA) model representing physically based constitutive models were developed to precisely predict the flow behaviour of AA2060 alloy sheet under a wide range of

T

and

\dot{ε}

. The predictability of the developed constitutive models was assessed and compared using various statistical parameters, including the correlation coefficient (R), average absolute relative error (AARE), and root mean square error (RMSE). By comparing the results determined from these models and those obtained from experimentations, and confirmed by R, AARE, and RMSE values, it is concluded that the predicted stresses determined from the S2-MJC model align closely with the experimental stresses, demonstrating a remarkable fit compared to the S1-MJC, L-MJC, and MZA models. This is because of the linking impact between softening, the strain rate, and strain hardening in the S2-MJC model. It is widely known that the dislocation process is affected by softening and strain rates. This is attributed to the interactions that occurred between

ε

and

\dot{ε}

from one side and between

ε

\dot{ε}

, and

T

from the other side using an extensive set of constants correlating the constitutive components of dynamic recovery and softening mechanisms. Full article

(This article belongs to the Special Issue Application of Advanced Metal-Forming Technology in Light-Weight Alloys)

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15 pages, 4823 KiB

Open AccessArticle

Coupling Computational Homogenization with Crystal Plasticity Modelling for Predicting the Warm Deformation Behaviour of AA2060-T8 Al-Li Alloy

by Ali Abd El-Aty, Sangyul Ha, Yong Xu, Yong Hou, Shi-Hong Zhang, Bandar Alzahrani, Alamry Ali and Mohamed M. Z. Ahmed

Materials 2023, 16(11), 4069; https://doi.org/10.3390/ma16114069 - 30 May 2023

Cited by 1 | Viewed by 1043

Abstract

This study aimed to propose a new approach for predicting the warm deformation behaviour of AA2060-T8 sheets by coupling computational homogenization (CH) with crystal plasticity (CP) modeling. Firstly, to reveal the warm deformation behaviour of the AA2060-T8 sheet, isothermal warm tensile testing was accomplished using a Gleeble-3800 thermomechanical simulator at the temperatures and strain rates that varied from 373 to 573 K and 0.001 to 0.1 s⁻¹. Then, a novel crystal plasticity model was proposed for describing the grains’ behaviour and reflecting the crystals’ actual deformation mechanism under warm forming conditions. Afterward, to clarify the in-grain deformation and link the mechanical behaviour of AA2060-T8 with its microstructural state, RVE elements were created to represent the microstructure of AA2060-T8, where several finite elements discretized every grain. A remarkable accordance was observed between the predicted results and their experimental counterparts for all testing conditions. This signifies that coupling CH with CP modelling can successfully determine the warm deformation behaviour of AA2060-T8 (polycrystalline metals) under different working conditions. Full article

(This article belongs to the Special Issue Application of Advanced Metal-Forming Technology in Light-Weight Alloys)

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11 pages, 3657 KiB

Open AccessArticle

Special-Oriented Annealing-Twins-Induced Orange Peel Morphology of Heat Pipe under Bending Deformation

by Song-Wei Wang, Hong-Wu Song, Shi-Hong Zhang and Shuai-Feng Chen

Materials 2023, 16(6), 2147; https://doi.org/10.3390/ma16062147 - 07 Mar 2023

Viewed by 1140

Abstract

The thin-wall heat pipe is an efficient heat transfer component that has been widely used in the field of heat dissipation of high-power electronic equipment in recent years. In this study, the orange peel morphology defect of thin-wall heat pipes after bending deformation was analyzed both for the macro-3D profile and for the micro-formation mechanism. The morphology and crystal orientations of the grains and annealing twins were carefully characterized utilizing optical metallography and the electron backscatter diffraction technique. The results show that after high-temperature sintering treatment, the matrix grains of the heat pipe are seriously coarsened and form a strong Goss texture, while certain annealing twins with the unique copper orientation are retained. The distribution of the Schmid factor value subjected to the uniaxial stress indicates that inhomogeneity in the intergranular deformation exists among the annealing twins and matrix grains. The annealing twin exhibits a “hard-oriented” component during the deformation; thus, it plays a role as a barrier and hinders the slipping of dislocation. As the strain accumulates, part of the annealing twins may protrude from the surface of the heat pipe, forming a large-scale fluctuation of the surface as the so-called “orange peel” morphology. The 3D profile shows the bulged twins mostly perpendicular to the drawing direction, about 200–300 in width and 10–20 μm in height. Full article

(This article belongs to the Special Issue Application of Advanced Metal-Forming Technology in Light-Weight Alloys)

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17 pages, 55854 KiB

Open AccessArticle

Hot Deformation Behavior and Processing Map Considering Strengthening Effect for Al–10.0Zn–3.0Mg–2.8Cu Alloy

by Si-Qi Wang, Xi Zhao, Xian-Wei Ren, Zhi-Min Zhang, Xue-Dong Tian and Ya-Yun He

Materials 2023, 16(5), 1880; https://doi.org/10.3390/ma16051880 - 24 Feb 2023

Cited by 2 | Viewed by 1325

Abstract

In this paper, a hot processing map that takes into the strengthening effect into account is optimized for the Al–10.0Zn–3.0Mg–2.8Cu alloy, mainly considering the crushing and dissolving behavior of the insoluble phase. The hot deformation experiments were performed by compression testing with strain rates ranging from 0.001 to 1 s⁻¹ and the temperature ranging from 380 to 460 °C. The hot processing map was established at the strain of 0.9. It exhibits that the appropriate hot processing region is located at the temperature from 431 to 456 °C and its strain rate is within 0.004–0.108 s⁻¹. The recrystallization mechanisms and insoluble phase evolution were demonstrated using the real-time EBSD-EDS detection technology for this alloy. It is verified that the work hardening can also be consumed by the coarse insoluble phase refinement with the strain rate increasing from 0.001 to 0.1 s⁻¹, besides the traditional recovery and recrystallization, but the effect of the insoluble phase crushing was weakened when strain rate increased over 0.1 s⁻¹. Better refinement of the insoluble phase was around strain rate in 0.1 s⁻¹, which exhibits adequate dissolving during the solid solution treatment, leading to excellent aging strengthen effects. Finally, the hot processing region was further optimized, so that the strain rate approaches 0.1 s⁻¹ instead of 0.004–0.108 s⁻¹. This will provide a theoretical support for the subsequent deformation of the Al–10.0Zn–3.0Mg–2.8Cu alloy and its’ engineering application in aerospace, defense and military fields. Full article

(This article belongs to the Special Issue Application of Advanced Metal-Forming Technology in Light-Weight Alloys)

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17 pages, 6085 KiB

Open AccessArticle

Plastic Deformation Mechanism of High Strength and Toughness ZK61 Magnesium Alloy Plate by Multipass Horizontal Continuous Rolling

by Ming Chen, Cong Ma, Qingjie Liu, Ming Cheng, Haolei Wang and Xiaodong Hu

Materials 2023, 16(3), 1320; https://doi.org/10.3390/ma16031320 - 03 Feb 2023

Cited by 2 | Viewed by 1540

Abstract

ZK61 magnesium-alloy plate with high tensile strength and elongation is obtained by combined multipass symmetric hot rolling and asymmetric warm rolling. Deformation history considering varying strain rate obtained from the macro-finite element analysis of the selected passes are introduced into the viscoplastic self-consistent model (VPSC) as initial boundary conditions for macro- multiscale and micro-multiscale coupling analysis. VPSC simulation results show that in the initial stage of rolling deformation, the basal <a> slip is the dominated deformation mode, supplemented by prismatic <a> slip and pyramidal <c+a> slip. With increased rolling strain, the pyramidal <c+a> slip presents competitive relationship with basal <a> slip, and the activation amount of {10

\overset{—}{1}

1} compression twins is limited. During asymmetric rolling, the basal <a> slip is dominant, followed by the pyramidal <c+a> slip. Experimental results show that the basal texture is gradually strengthened after symmetric rolling, and grain size is refined due to the activation and recrystallization of twins. Asymmetric rolling makes the basal texture deflect 10° to the rolling direction and further refine the grain size. With the ongoing of symmetric rolling, the mechanical anisotropy of the plate weakens, and the yield strength, tensile strength, and plasticity of the material improves. In particular, after asymmetric rolling, the tensile strength in the RD and TD directions of the plate reaches 391.2 MPa and 398.9 MPa, whereas the elongation reaches 19.8% and 25.5%. Full article

(This article belongs to the Special Issue Application of Advanced Metal-Forming Technology in Light-Weight Alloys)

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15 pages, 16970 KiB

Open AccessArticle

Effect of Hot Metal Gas Forming Process on Formability and Microstructure of 6063 Aluminum Alloy Double Wave Tube

by Yong Xu, Xiu-Wen Lv, Yun Wang, Shi-Hong Zhang, Wen-Long Xie, Liang-Liang Xia and Shuai-Feng Chen

Materials 2023, 16(3), 1152; https://doi.org/10.3390/ma16031152 - 29 Jan 2023

Cited by 2 | Viewed by 1599

Abstract

The hot metal gas forming process can significantly improve the formability of a tube and is suitable for the manufacturing of parts with complex shapes. In this paper, a double wave tube component is studied. The effects of different temperatures (400 °C, 425 °C, 450 °C and 475 °C) and different pressures (1 MPa, 1.5 MPa, 2 MPa, 2.5 MPa and 3 MPa) on the formability of 6063 aluminum alloy tubes were studied. The influence of hot metal gas forming process parameters on the microstructure was analyzed. The optimal hot metal gas forming process parameters of 6063 aluminum alloy tubes were explored. The results show that the expansion rate increases with the increase in pressure. The pressure affects the deformation of the tube, which in turn has an effect on the dynamic softening of the material. The expansion rate of parts also increases with the increase in forming temperature. The increased deformation temperature is beneficial to the dynamic recrystallization of 6063, resulting in softening of the material and enhanced deformation uniformity between grains, so that the formability of the material is improved. The optimum hot metal gas forming process parameters of 6063 aluminum alloy tubes are the temperature of 475 °C and the pressure of 2.5 MPa; the maximum expansion ratio is 41.6%. Full article

(This article belongs to the Special Issue Application of Advanced Metal-Forming Technology in Light-Weight Alloys)

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21 pages, 6766 KiB

Open AccessArticle

Experimental Analysis and Parametric Optimization on Compressive Properties of Diamond-Reinforced Porous Al Composites

by Bisma Parveez, Nur Ayuni Jamal, Abdul Aabid, Muneer Baig and Farazila Yusof

Materials 2023, 16(1), 91; https://doi.org/10.3390/ma16010091 - 22 Dec 2022

Cited by 2 | Viewed by 1599

Abstract

The present study aims to optimize the compressive properties of porous aluminum composites fabricated using the powder metallurgy (PM) space holder technique. These properties were optimized by taking into consideration different processing factors such as sintering temperature, compaction pressure, and sintering time. The experimental design was formulated using L₉ orthogonal array by employing these three parameters at three levels. The density, porosity, plateau stress, and energy absorption capacity were determined and analyzed. The impact of individual input parameters was evaluated using the Taguchi-based S/N ratio and analysis of variance (ANOVA). The main effect plots outlined the optimum parameter levels to achieve maximum values for compressive properties (plateau stress and energy absorption capacity). The results revealed that the sintering temperature and time significantly impact compressive properties. The ANOVA analysis exhibited similar results, with maximum contribution from sintering temperature. Further response optimization of compressive properties concluded that the maximum values could be achieved at optimum parameters, i.e., a sintering temperature of 590 °C, compaction pressure of 350 MPa, and sintering time of 90 min. Further, confirmation tests on the optimized parameters revealed improved results and some minor errors and deviations indicating that the selected parameters are vital for controlling the compressive properties of the aluminum composites. Full article

(This article belongs to the Special Issue Application of Advanced Metal-Forming Technology in Light-Weight Alloys)

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16 pages, 9258 KiB

Open AccessArticle

Cold Roll Forming Process Design for Complex Stainless-Steel Section Based on COPRA and Orthogonal Experiment

by Jing Wang, Hua-Min Liu, She-Fei Li and Wan-Jun Chen

Materials 2022, 15(22), 8023; https://doi.org/10.3390/ma15228023 - 14 Nov 2022

Cited by 2 | Viewed by 1656

Abstract

Cold roll forming can fabricate products with complex profiles, and its parameter optimization can achieve high quality and improved precision of products. In this paper, taking the side shield as a typical product, the cold roll forming of a complex section of stainless steel SUS301L-ST is analyzed, establishing a 3D finite element model by using the professional roll forming software COPRA. We propose a floating roll device for complex sections with asymmetry and large depth. We use an orthogonal experiment to obtain the inter-distance between rolls, friction coefficients, the diameter increments, and line velocities to investigate the effects on the maximum longitudinal strain of the edge. Results show that the diameter increment has the greatest influence on the maximum strain, and its increases can reduce the strain. The inter-distance value needs a suitable range. A small value is not conducive to the release of elastic deformation, while a large value will cause unexpected displacement and increase the cost. The friction coefficient increases; although it helps to reduce the strain, it will cause scratches and other defects on the stainless steel. The increase in velocity increases the strain. We derive the optimal parameters for the complex section, providing a theoretical basis for practical production. Full article

(This article belongs to the Special Issue Application of Advanced Metal-Forming Technology in Light-Weight Alloys)

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18 pages, 8332 KiB

Open AccessEditor’s ChoiceArticle

Influence of Grain Orientation and Grain Boundary Features on Local Stress State of Cu-8Al-11Mn Alloy Investigated Using Crystal Plasticity Finite Element Method

by Ce Zheng, Lijun Xu, Xiaohui Feng, Qiuyan Huang, Yingju Li, Zhongwu Zhang and Yuansheng Yang

Materials 2022, 15(19), 6950; https://doi.org/10.3390/ma15196950 - 07 Oct 2022

Cited by 2 | Viewed by 1492

Abstract

Reducing the local stress in the vicinity of the grain boundaries is a favorable way to improve the super-elastic properties of super-elastic alloys. The crystal plasticity finite element method (CPFEM) was applied in this study to simulate the deformation behavior and local stress of a super-elastic Cu-8Al-11Mn (wt.%) alloy containing single grains with various orientations, columnar grains with different misorientation angles, and tri-crystals with distinct grain boundary morphologies. The results indicated that the stress distribution of single grains presented obvious orientation dependence during deformation. Uniformly distributed stress was observed in grains with orientations of 0° and 90° when more slip systems were activated during deformation. With the increase in the misorientation angles of columnar grains, the stresses in the vicinity of the grain boundaries increased, which was related to the difference in the shear stress of the slip systems in adjacent grains. When the difference in the shear stress of the slip systems in two adjacent grains was large, a local stress concentration formed in the vicinity of the grain boundary. Compared with the triple-junction grain boundaries, the local stresses of the straight and vertical grain boundaries were smaller, which was closely related to the number of activated slip systems on both sides of the grain boundary. The above results were obtained experimentally and could be used to design super-elastic alloys with high performance. Full article

(This article belongs to the Special Issue Application of Advanced Metal-Forming Technology in Light-Weight Alloys)

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19 pages, 15266 KiB

Open AccessArticle

A Novel Hydroforming Process by Combining Internal and External Pressures for High-Strength Steel Wheel Rims

by Wei-Jin Chen, Yong Xu, Hong-Wu Song, Shi-Hong Zhang, Shuai-Feng Chen, Liang-Liang Xia, Yong Wang, Boris-B. Khina and Artur-I. Pokrovsky

Materials 2022, 15(19), 6820; https://doi.org/10.3390/ma15196820 - 30 Sep 2022

Cited by 4 | Viewed by 1545

Abstract

As one of the key safety components in motor vehicles, the steel wheel rim is commonly fabricated with the roll forming process. However, due to the varied cross-sections of the rim and the low formability of high-strength steel, it is difficult to produce thin-wall and defect-free wheel rims to realize the purpose of light weight. To solve these problems, a novel hydroforming process by combining internal and external pressures (HIEP) was proposed to produce thin-wall wheel rims in the current study. The designed initial tube with diameter between the maximum and minimum diameter of the wheel rim ensures dispersed deformation and effectively avoids local excessive thinning. During HIEP, a hydroforming process was performed with two successive stages: the external pressure and internal pressure stages. Theoretical analysis and finite element method (FEM) were jointly used to investigate the effect of process parameters on the wrinkling and thinning. With the optimized parameters for internal and external pressure, the wrinkling of wheel rims is prevented under compressive state during the external pressure forming stage. Additionally, HIEP was experimentally carried out with high-strength steel rims of 650 MPa ultimate tensile strength (UTS). Finally, wheel rims with weight reduction of 13% were produced successfully, which shows a uniform thickness distribution with a local maximum thinning ratio of 11.4%. Full article

(This article belongs to the Special Issue Application of Advanced Metal-Forming Technology in Light-Weight Alloys)

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Review

Jump to: Research

54 pages, 17421 KiB

Open AccessEditor’s ChoiceReview

A Review of Characterization and Modelling Approaches for Sheet Metal Forming of Lightweight Metallic Materials

by Yong Hou, Dongjoon Myung, Jong Kyu Park, Junying Min, Hyung-Rim Lee, Ali Abd El-Aty and Myoung-Gyu Lee

Materials 2023, 16(2), 836; https://doi.org/10.3390/ma16020836 - 15 Jan 2023

Cited by 20 | Viewed by 5086

Abstract

Lightweight sheet metals are attractive for aerospace and automotive applications due to their exceptional properties, such as low density and high strength. Sheet metal forming (SMF) is a key technology to manufacturing lightweight thin-walled complex-shaped components. With the development of SMF, numerical simulation and theoretical modelling are promoted to enhance the performance of new SMF technologies. Thus, it is extraordinarily valuable to present a comprehensive review of historical development in SMF followed by state-of-the-art advanced characterization and modelling approaches for lightweight metallic materials. First, the importance of lightweight materials and their relationship with SMF followed by the historical development of SMF are reviewed. Then, the progress of advanced finite element technologies for simulating metal forming with lightweight alloys is covered. The constitutive modelling of lightweight alloys with an explanation of state-of-the-art advanced characterization to identify the constitutive parameters are presented. Then, the formability of sheet metals with major influencing factors, the techniques for measuring surface strains in SMF and the experimental and modelling approaches for determining the formability limits are clarified. Finally, the review is concluded by affording discussion of the present and future trends which may be used in SMF for lightweight metallic materials. Full article

(This article belongs to the Special Issue Application of Advanced Metal-Forming Technology in Light-Weight Alloys)

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24 pages, 8983 KiB

Open AccessReview

Deformation Characteristics, Formability and Springback Control of Titanium Alloy Sheet at Room Temperature: A Review

by Hao Li, Shuai-Feng Chen, Shi-Hong Zhang, Yong Xu and Hong-Wu Song

Materials 2022, 15(16), 5586; https://doi.org/10.3390/ma15165586 - 15 Aug 2022

Cited by 4 | Viewed by 2159

Abstract

Titanium alloy sheets present inferior formability and severe springback in conventional forming processes at room temperature which greatly restrict their applications in complex-shaped components. In this paper, deformation characteristics and formability and springback behaviors of titanium alloy sheet at room temperature are systematically reviewed. Firstly, deformation characteristics of titanium alloys at room temperature are discussed, and formability improvement under high-rate forming and other methods are summarized, especially the impacting hydroforming developed by us. Then, the main advances in springback prediction and control are outlined, including the advanced constitutive models as well as the optimization of processing paths and parameters. More importantly, notable springback reduction is observed with high strain rate forming methods. Finally, potential investigation prospects for the precise forming of titanium alloy sheet in the future are suggested. Full article

(This article belongs to the Special Issue Application of Advanced Metal-Forming Technology in Light-Weight Alloys)

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