AA 2024-T3 Research Articles

Low-Temperature Mechanical Properties of AA 6063-T6 and 7075-T6: Tests and Full-Range Constitutive Models

Low-Temperature Mechanical Properties of AA 6063-T6 and 7075-T6: Tests and Full-Range Constitutive Models

Springback behavior after air bending of pre-strained AA 6016-T4 sheets: Influence of dislocation density and backstress on model accuracy

Predicting springback in sheets of aluminum alloys is challenging, particularly for complex strain path deformation used to form the material. This paper presents experimental and modeling results for air bending of AA 6016-T4 sheet material. Prior to bending, pre-strains were applied to the specimens in uniaxial tension, plane-strain tension, and biaxial tension. Specimens were then cut from the pre-strained material and were subjected to air bending using three different bend angles in a v-die, after which springback was measured. It was found that greater levels of pre-strain result in larger springback magnitudes, and that the biaxial pre-strained specimens generally exhibited greater springback than the others. A CPFE – EPSC model with phenomenological backstress component in the hardening law was used to predict springback magnitude across the different pre-strain paths, pre-strain levels, and imposed air bend angles. It was observed that the more significant the strain path change, as was seen in the case of biaxial tension pre-strain followed by bending, the greater the influence of backstress on model accuracy, owing to the activation of new slip systems. When backstress was excluded from the model, a 3.2 % prediction error in springback angle was observed in the worst case, versus an error of 0.8 % when backstress was included. Backstress was correlated to more rapid dislocation density development on both the tensile surface of the sheet, and also through the thickness, after the strain path change. On the other hand, for the case of plane-strain pre-strain followed by bending, dislocation density development was more gradual and the backstress impact on model prediction was less significant, with the same slip systems active during both pre-strain and bending. Therefore, it is seen that the influence of backstress on accuracy springback modeling in AA 6016-T4 varies significantly depending on the strain path. Thus, the use of a phenomenological backstress law within the CPFE-EPSC framework is seen to be an accurate and efficient approach for modeling springback after strain path changes that can occur during industrial forming applications.

Electroplasticity constitutive modeling of aluminum alloys based on dislocation density evolution

Electrical current can effectively improve the plasticity of metallic materials. The tensile deformation behavior of Al alloys under the pulsed electrical current assisted quasi-static unidirectional tension (EAT) has been investigated. Materials under the EAT exhibits periodic electro-softening and strain-hardening behaviors, i.e., a ratchet shape mechanical response. However, establishing a constitutive model to accurately predict the ratchet shape mechanical behavior, especially during the EAT interval, and accurately predicting the strain-hardening behavior of materials are critical issues that need to be solved urgently. In this study, based on the Taylor polycrystalline model, thermal activation theory and dislocation density evolution theory, a two-parameter dislocation density electroplasticity constitutive model with forward and reverse dislocation density evolution was developed to describe the periodic coupling effect of the electro-thermal-mechanical fields during EAT. The tensile deformation behaviors of AA 6061-T6 and AA 7075-T6 under the effect of a pulsed electrical current were quantitatively predicted using the proposed constitutive model. The results show that the correlation coefficient between the predicted and experimental results of the constitutive model can reach 0.84–0.99, implying that the proposed constitutive model can accurately predict the complex electroplasticity behavior of Al alloys during EAT.

Toolpath and Tool Design Innovations in Deformation Machining for Superior AA-7075 T6 Fins

Abstract A hybrid manufacturing process, deformation machining (DM) combines subtractive manufacturing with incremental forming. Monolithic components with complex profiles are created through the hybridization of manufacturing technologies, which also reduces the wastage of raw materials. The properties of geometry and surface quality of the fin made from the aluminum alloy Al-7075 T6 using the DM process’s bending mode was examined in this research, as were the effects of various approaches, toolpath methods, and tool design. To achieve the desired shape for the machined fin, various combinations of arcuate and slanting fin toolpath techniques were explored utilizing both top-down and bottom-up methods. The bottom-up method and the arcuate toolpath strategy were used to investigate various tool profiles. Using the best combination of toolpath strategy and tool profile, named as the T3 tool profile, which has a 0.6 mm nose radius and a circular sector, bottom-to-top (BTT)technique, and arcuate toolpath method, components with better geometrical features and surface roughness (SR) were produced. The analysis of the forming force in the bending approach of the DM progression was further carried out using this optimal combination.

Enhancing strength performance of laser welded 7075 aluminum alloy joints with TiC nanoparticle-mixed filler powder

Precipitation-strengthened 7075 aluminum alloy (AA 7075) is a crucial structural material widely utilized in the aerospace industry. Nevertheless, the achievement of highly strengthened joints of this alloy remains a challenge because of its susceptibility to composition dilution and defect formation during welding. In this study, the method of powder-filled laser welding was employed to weld AA 7075-T6 plates, utilizing both AA 7075 powder and a mixed powder of AA 7075 and 5 wt % TiC nanoparticles as the filler. To investigate the impact of the filler on the mechanical properties of the welded joints, their microstructure, phase constitution and tensile strength were measured and analyzed. Moreover, the transient temperature and the forming process of the joints during laser welding were captured. The results indicate that the joints are heat-treatable when the filler contains the AA 7075 powder. The ultimate tensile strength (UTS) of the joints can reach 500 MPa as a result of the η′ phase precipitated during heat treatment. The incorporation of TiC nanoparticles into the AA 7075 powder led to a refinement of grains, a reduction in porosity within the joints and an increase in the UTS by up to 540 MPa, which is 91.5 % of the base metal. Further theoretical estimation suggests that Orowan strengthening as well as grain size strengthening due to the Hall-Petch effect are the main strengthening mechanisms for the improved tensile performance. The powder-filled laser welding method also provides a flexible approach for designing compositions of filler material.

An uncoupled ductile fracture criterion for a wide range of stress states in sheet metal forming failure prediction

In industrial production, sheet metal rupture will inevitably occur in the process of forming, especially in the shape of complex, relatively small thickness of the sheet. It is vital to accurately predict the failure of ductile metals under various working conditions. To deal with the problem, an uncoupled ductile fracture criterion (DFC) for a broad range of stress states is proposed based on the micro-mechanism of ductile fracture of metals, which redefines the relationship between the number of void nucleating and the equivalent plastic strain and takes into account the different deformation modes of the voids in the growth stage. Then, in order to verify the validity and advantages of the proposed DFC, the 3D fracture surface of AA 2024-T351 and AISI 1045 steel are constructed by the new criterion based on their fracture data under various stress states, and compared with the commonly used DF2016 criterion and Hu criterion. The prediction results show that the new criterion is better than them, both in terms of the maximum prediction error and the average prediction error. Furthermore, to further prove the effectiveness of the proposed model, five samples are designed for tension tests to calibrate the new DFC using a hybrid experimental–numerical approach, and the calibrated criterion is applied to cupping simulations of AA 6061 and compared with cupping experimental results. The results indicate that the Erichsen cupping number (IE) of the cupping simulation and experiment are 6.88 mm and 7.05 mm, respectively, and the error between them is only 2.411 %, and the location of the fracture is also basically the same. Therefore, all comparison results show that the proposed DFC can forecast the fracture problem in sheet forming more accurately under various stress states.

Spatially Resolved Assessment and Analysis of Al-Zn, Mg, and Mg/Al-Zn Metal-Rich Primers Applied to AA 7075-T651 in Full Immersion

The scanning vibrating electrode technique (SVET) was utilized to monitor localized corrosion and substrate protection of three metal-rich primers (MRP). The ability to suppress localized corrosion and provide widespread cathodic polarization to enable sacrificial anode-based cathodic protection of a AA 7075-T651 substrate with either an aluminum-rich primer (AlRP), magnesium-rich primer (MgRP), or a composite magnesium + aluminum-rich primer (MgAlRP) in a polyamide-based epoxy primer coatings fully immersed in 1 mM NaCl was investigated. Pigments did not activate uniformly in each MRP. The notion of throwing power polarizing the bare substrate and uniform current and potential distributions at scratch sites does not describe the behavior observed. In cases where activation occurred, protection was noticed in the form of suppression of local anodes on bare AA 7075-T651. Local corrosion was suppressed on heterogeneously corroding AA 7075-T651 with strong local anodes and cathodes. Widespread cathodic polarization was absent. The MgRP and MgAlRP were shown to provide superior local corrosion suppression associated with pitting on AA 7075-T651 compared to the AlRP.

FSW of AA2024: effects of tool wear on energy consumption

ABSTRACT This study shows that the progressive adhesion of weld material to the tool in friction stir welding AA 2024-T3, up to tool saturation, brings about a decrease in power consumption until a plateau is reached. The cause of this behavior is the hindering of the stirring action of the tool due to the material accumulated on it. The built-up material changes the nature of the tool/material interaction and then the friction condition at their interface. The direct consequence is a decrease in the shearing strain and therefore in the heat generated by friction. Bits of this adhering material break off from the tool at intervals. Macro and micro detachments are identified. Micro-detachments happen continuously at small periodic intervals and produce vibrations. The amplitude of these vibrations increases in all their characteristic spectral components up to tool saturation. Macro-detachments generate oscillations in power consumption and leave galling on the weld bead.

Effect of Process Parameters on Strength and Surface quality of Friction stir welded AA 6063-T6 Aluminum Alloy

Effect of Process Parameters on Strength and Surface quality of Friction stir welded AA 6063-T6 Aluminum Alloy

Exploring temperature and stress dynamics in AA 6082-T6 friction stir welding: a comprehensive experimental and finite element analysis

Exploring temperature and stress dynamics in AA 6082-T6 friction stir welding: a comprehensive experimental and finite element analysis

Integrating Numerical Simulation and Experimental Validation to Analyze Temperature Distribution in Friction Stir Welding of Dissimilar Aluminum Alloy

This study explores the temperature distribution in Aluminum alloys, specifically AA2024 T351 and AA6351 T6, during friction stir welding (FSW). Utilizing COMSOL Multiphysics software, the research investigates FSW at rotational speeds of 800, 1200, and 1600 rpm, while maintaining a constant welding speed (35 mm/min) and axial force (3 kN). The simulation incorporates temperature-dependent material properties. The findings reveal that the maximum temperature occurs at the upper part of the stir zone for both alloys. Experimental validation demonstrates excellent agreement with the simulated temperature distribution, reaffirming the accuracy of the COMSOL Multiphysics model.

Influence of material in sheet-bulk metal forming from coil

AbstractSheet-bulk metal forming (SBMF) represents an innovative approach for the efficient manufacturing of functional integrated parts from sheet metal by applying bulk forming processes to sheet metal. It combines the advantages of part weight optimization and process chain shortening. In view of the increasing demand for functionally integrated components, the forming from coil offers an economical possibility to produce high output rates. Nevertheless, an underfilling of functional elements as well as an asymmetric part forming are current challenges. In order to apply SBMF from coil in industrial contexts, it is necessary to understand the causes of these process limits and to develop measures for improving the forming of functional elements and thereby push existing forming limits. In this paper, both a lateral and a backward extrusion process from coil for the forming of internal and external geared SBMF parts are investigated to develop a fundamental process understanding. In a combined numerical-experimental approach, the influence of the flow behavior of different materials as well as the impact of the main material flow direction of the process on the dimensional part accuracy is analyzed. This enables the evaluation of fundamental material-related dependencies and influences regarding the geometrical part accuracy, the mechanical component properties and the tool load for forming of the conventional deep-drawing steel DC04 (t0 = 2 mm), a high-strength steel material (HC260LA) and an aluminum alloy (AA6082 T6). Based on these findings, measures for material flow control are identified and investigated to counteract the challenges of SBMF from coil. These findings permit the identification of potential transferability of the identified cause-effect mechanisms to different processes, component geometries and materials. Thereby, in particular, an increase in coil width as well as lower a strain hardening behavior of the material offers the possibility to improve the geometrical accuracy of the components.

Correlated 4D-STEM and EDS for the classification of fine Beta-precipitates in aluminum alloy AA 6063-T6

Tuning the properties of aluminum alloys AA 6063-T6 involves artificial aging to induce precipitate formation, particularly β’’ and β’ phases. Previous characterization challenges due to their similar appearance are addressed here by correlating 4D scanning transmission electron microscopy (4DSTEM) and energy-dispersive spectroscopy (EDS) mapping. This approach allows us to analyze the structure and composition of precipitates individually, overcoming limitations of conventional imaging and structural analysis techniques when the precipitates appear simultaneously, as is often the case. We present detailed characterizations of needle-shaped Beta precipitates, revealing distinct diffraction patterns (DPs) and compositional differences. The method's applicability extends beyond aluminum alloys, offering a promising strategy for complex composite material characterization with multimodal scanning transmission electron microscopy (STEM) techniques.

Forming quality and static properties of self-piercing riveted joints of hot-rolled steel and aluminum alloy sheets

The self-piercing riveting (SPR) Forming and tensile tests of hot-rolled steel sheet BR1200HS and aluminum alloy sheet AA 6082-T6 were simulated by Simufact Forming software. The test results show that the diameter of the rivet leg opening, which is the most important parameter affecting the mechanical properties of the joints, shows a first increase and a second decrease with the increase of rivet length, and the Max. tensile loads of the joints have the same variation law. The larger the diameter of the rivet leg opening, the greater the Max. tensile load of the joint, and the greater the effective plastic strain of the rivet of the joint. The rivet length of the joints in the five preferred SPR formation schemes obtained were all 6.5 mm, and only one scheme had a rivet hardness of H4, the rest were H5. The SPR experiment is used to verify the current finite element simulation data can get the final research conclusion. The finite element simulation (FEM) would greatly reduce the test times of the SPR test, save the test consumables and save the test cost.

Analysis Of Energy Absorption In Crash Box With Variation Of Trigger Hole Cyrcle Model Using Experimental Tests

Traffic accidents kill people every day and a large number of people are injured or killed in car accidents, safety in the automotive industry is being researched extensively. Every year, more than 1.2 million people are killed and ten million are injured in traffic accidents worldwide. Crash boxes as passive safety in vehicles continue to be modified to increase their ability to absorb energy. In this research, 3 crash box models were designed with a frusta model using Aluminum AA 6061-T4. Modeling was carried out using Solidwork software and testing using a Universal Testing Machine. From Experimental test results show that the Frusta 1 hole model crash box has the largest energy absorption capacity compared to other models, 1132.8 J with a force of 118 kN at a displacement of 28.32 mm. This shows that providing the Frusta model with a hole as a trigger provides an increase in the crash box's ability to absorb energy.

Investigating the effect of stress ratio on fatigue crack growth rate behaviour in friction stir welded AA7075-T651 aluminium alloy plates

This study examines the characteristics of Fatigue Crack Growth Rate (FCGR) in AA 7075-T651 Friction Stir Welded (FSW) joints with a thickness of 16 mm. Compact tension (CT) specimens from both the base and the FSW joints were utilized to assess FCGR under various stress ratios (0.2 to 0.5). Additionally, the study involved analyzing the transverse tensile characteristics of both the based and the welded joints. The microstructures of the welds were inspected using optical and transmission electron microscopes. Findings indicate that the FSWjoint critical stress intensity factor range (ΔKcr)is lower than the unwelded base, that can be related to precipitates dissolving in the weld zone when the friction stir welding process. Consequently, in contrast to the unwelded base, the fatigue life of AA 7075-T651 aluminium alloy FSW joints is significantly reduced. A scanning electron microscope carried out microstructural analyses of the fracture surfaces of the FSW and base under various stress ratioconditions. The results showed that, in contrast to the parent material, the FSW joint has ultra-fine grains resulting in intergranular cracks in the propagation zone.

Characteristics analysis and monitoring of friction stir welded dissimilar AA5083/AA6061-T6 using acoustic emission technique

The joining of aluminum alloys using fusion welding often leads to issues such as hot tears, porosity, distortion, and solidifying cracks. To address these challenges, solid-state welding processes like Friction Stir Welding (FSW) are preferable. This study investigates the FSW of dissimilar aluminum alloys AA 5083 and AA 6061-T6, employing Acoustic Emission (AE) techniques for real-time monitoring. FSW was conducted under conditions with no defects, pinhole defects, and piping defects. The resulting joints were evaluated for their mechanical properties and metallurgical characteristics. Microstructural analysis was performed using an optical microscope, revealing that the defect-free condition achieved the highest tensile strength of 256 MPa and superior hardness of 93 HV at the stir zone. Tensile failure commonly manifested within the heat-affected zone (HAZ) of AA 6061-T6, primarily due to grain enlargement and the impact of Mg2Si precipitates. Examination of the fractured regions via scanning electron microscopy revealed ductile-mode fractures featuring elongated dimples and microvoids. AE parameters such as hits, amplitude RMS, and energy were analyzed, demonstrating that defect-free welds had consistent AE signal patterns, while significant variations were observed in pinhole and piping defect conditions due to larger defect areas. The findings suggest that AE monitoring is effective in detecting and analyzing welding defects, providing valuable insights into the FSW process for dissimilar aluminum alloys.

Assessment of the Thermomechanical Behavior and Microstructure of AA 7075-T6 Aluminum Alloy Lap Joints at Optimal Predicted FSW Process Parameters

The lap joints of AA 7075-T6 aluminum alloy were assembled using the friction stir welding (FSW) technique. Experimental studies were performed to characterize the thermomechanical properties of these welds. The main goal of this research was to comprehensively assess the thermomechanical behavior of AA 7075-T6 aluminum alloy under FSW conditions. Tests were carried out at a tool rotational speed of 1320 rpm and at two advancing speeds of 70 mm/min and 120 mm/min, selected based on a previous study aiming to optimize the heat input during the FSW process. The experimental investigations involved the characterization of temperature profiles during welding, mechanical properties such as microhardness and tensile strength, and microstructure examination at the two advancing speed conditions. This study revealed that the welding speed has an obvious influence on the material thermal behavior during the FSW process. Indeed, the peak temperature obtained with a lower welding speed (70 mm/min) was higher by almost 10% compared to that obtained with a higher speed (120 mm/min). Moreover, by increasing the welding speed, the mechanical characteristics, such as microhardness and tensile strength, were increased by almost 5% for the mean microhardness and 6% for the ultimate tensile strength. Additionally, the microstructure examination demonstrated that, by decreasing the welding speed, more interaction between the tool and the material is observed, resulting in a deeper stir zone due to increased heat dissipation downwards into the material, affecting the thermal profile and influencing the resulting mechanical properties of the welded joint.

A 90-meter Split Hopkinson Tension–Torsion Bar: Design, Construction and First Tests

AbstractThis article describes the design, construction, and first experimental results of a 90 m-long Hopkinson bar which can perform high strain rate tests in a combined tension–torsion state. The system configuration is analogous to the classic Hopkinson bar technique, consisting of three bars: a pre-stressed bar, an input bar, and an output bar; the sample is placed between the input and output bar. The measurement is also based on the classical three-wave method, where the incident, transmitted and reflected waves are measured. Incident compression and torsional waves are simultaneously generated by the failure of a fragile element that connects the pre-stressed bar to electromechanical actuators; the indirect Hopkinson tension bar technique is exploited, where the compression wave reaches the end of the output bar without stressing the sample and is reflected as a tensile input wave. The length of the bars is designed so that the tensile wave reaches the sample from the output bar side at the same time as the torsion wave comes from the input bar. Void tests were carried out first, for preliminary analysis of the system behaviour. Then, successful tests have been conducted on samples made of AA7075 T6, both in combined and pure tension–torsion states; it has been possible to measure the tension–torsion stress–strain curves, from which the equivalent flow stress–strain curve has been evaluated and compared to the quasi-static ones.

Failure evaluation on tailor made aerospace aluminum alloys via underwater friction stir welding employing predictive machine learning technologies

Employing tailor-made alloys with uneven thickness achieves light weighting, a critical issue for reducing emissions, leading to lower aircraft pollutants and fuel costs. The research utilizes advanced machine learning techniques such as Gaussian process regression (GPR), artificial neural networks (ANN) linear regression (LR), and support vector machines (SVM) to predict the ultimate tensile strength of underwater friction stir welding of AA6082-T6 and A2219-T83 tailor-made joints. The models have been evaluated with an assortment of kernel functions, including the polynomial kernel (PK), the radial basis function (RBF), and the Pearson VII universal kernel (PUK). To acquire experimental data, we used a Central Composite Design (CCD) technique, incorporating various factors in the process encompassing tool tilt angle (TA), rotating speed (RS), and welding speed (WS). The SVM radial basis function model (SRBP) had a maximum correlation coefficient of 0.9995 and a minimum root mean square error value (RMSE) of 0.5433 in the training set and 0.6271 in the test set. The ANN model predicted the UTS with an error margin of 0.21%, while the SRBP model showed a 0.52% error, and the LR model exhibited a significantly higher error of 7.73%. A peak tensile strength of 252.98 MPa was recorded in the S20 specimen, accounting for 85.61% of the base metal’s (AA6082 T6) strength. A reduced acute tearing ridge indicates petite, shallow dimples due to the inherent cooling. Through the analysis of metrics and residuals, high accuracy rates were observed when employing the ANN and SRBP models to predict mechanical traits.