Abstract
6XXX series aluminum alloys are generally excellent alternatives to steels for many forged parts in aerospace and automotive industries. In this study, the forging performance of the 6082 aluminum alloy is investigated in order to replace the existing material for forged steel parts. The effect of artificial aging of the alloy on the microstructure and mechanical properties is studied. Optimum aging conditions are determined. Results reveal that AA6082 could be a good replacement for applications where shock and vibrational loads exist. The rod end automotive part currently manufactured from AISI1045 can be replaced by AA6082 without any design changes. The major drawback is that the cold forging of the aged alloy is poor due to its brittle nature and crack initiations. Therefore, warm or hot forging is recommended to overcome the poor forgeability.
Highlights
Reducing the fuel consumption and carbon dioxide emissions is a challenging issue in automotive industry
The rod end part currently manufactured from AISI1045 can be replaced by AA6082 without any design changes
It is seen that the aging leads to a decrease in formability since the maximum strain is seen in AA6082-O, where artificial aging is not applied
Summary
Reducing the fuel consumption and carbon dioxide emissions is a challenging issue in automotive industry. Mechanical properties improved by aging process are comparable to the steels This alloy has the potential to be a good replacement for steel parts in the suspension, chassis, and engine. A change in design can irrevocably lead to additional development time, proses, and expertise costs for the manufacturers since the part needs to meet the same set of requirements It is well-known that trial and error process is not a cost effective method. The artificial aging after the hot forging leads to a homogeneous grain distribution in the microstructure [9]. The alloy is sensitive to deformation rate during forging, and its tensile strength increases at high strain rates [17]. AA6082 alloy presents high flexibility in terms of mechanical properties depending on the heat treatment and deformation conditions. Press force requirement for forging, the burr ratio, the processing time, the residual stress, the deformation, and the service life of the rod end were compared
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