Formability Of Magnesium Alloys Research Articles

Effect of equal channel angular pressing on magnesium alloys − A review

Magnesium (Mg) alloys own excellent properties that includes better castability, low density and great specific strength. Mg and its alloys are easily available and economical. Necessity of Mg and its alloys for manufacturing and engineering purposes has increased, predominantly in the area of aircraft and automobile applications. The known limitation of magnesium is its poor formability at room temperature, with inadequate slip systems due to hexagonal closed packed construction of magnesium. Formability of magnesium alloys will be enhanced at room temperature by grain structure refinement which improves ductility with grain refined structure. Severe plastic deformation (SPD) procedure induces extreme strain within the sample to produce ultrafine grained structure. Additionally, few shortcomings of magnesium is increased wear mass loss and corrosion rate obstructing the use of Mg and its alloys in several industrial appliances. Wear resistance and corrosion behaviour can be enhanced by SPD thereby increasing the requirement of magnesium alloys for engineering applications. Among SPD, equal channel angular pressing (ECAP) is an efficient approach to develop and vary the mechanical and microstructural properties as per the need. In ECAP approach, the workpiece undergoes shear deformation and large strains are induced in the workpiece with no variation in cross sectional aspect of the workpiece. Microstructure plays a very important role in achieving the required mechanical properties. ECAP process creates ultrafine-grained microstructure with different number of ECAP passes with varying temperatures inducing high strain rate.

Finite element simulations and experimental investigations on formability of magnesium alloys in superplastic forming

The paper presents the formability aspects of magnesium alloy (AZ31B) sheets into regular and intricate shapes during Super Plastic Forming (SPF). Finite Element (FE) simulations are performed at specific strain rates within the superplastic temperature range. The formability of 1 mm sheet into conical, cylindrical, box and groove shaped dies are simulated. The simulated Pressure-Time (P-T) curve is given as pressure control algorithm to form the shapes experimentally. Thickness strains of the experimentally formed components validated with simulation results are found to be in close agreement with each other. It is demonstrated by the analysis that regular shapes posses uniform thickness distribution throughout the profile. The components with complex intricate shapes recorded unevenness in thinning behavior. The unevenness in thinning is influenced by the Grain Boundary Sliding (GBS) and diffusion kinetics. GBS is well controlled by optimum P-T algorithm to produce sharp intricate shapes with uniform thickness.

Influence of extrusion method on the microstructure and mechanical properties of formed magnesium alloy tubes

Influence of extrusion method on the microstructure and mechanical properties of formed magnesium alloy tubes

Microstructural and Textural Investigation of an Mg-Zn-Al-Ca Alloy after Hot Plane Strain Compression.

The formability of magnesium alloys can be significantly improved by Ca as an alloying addition. Compared to conventional alloy sheets such as AZ31, texture modification can be found in rolled Mg-Ca sheets, which reveal a randomized orientation distribution. The hot deformation behavior of a twin-roll cast and homogenized Mg-2Zn-1Al-0.3Ca (ZAX210) alloy was characterized during hot compression at a temperature of 350 °C and strain rates of 0.1 s-1 and 10 s-1. Electron backscatter diffraction (EBSD) analysis was performed in order to describe the microstructural and texture evolution. The ZAX210 alloy exhibits a pronounced dynamic recrystallization (DRX) behavior during compression at high strain rates, while at lower strain rates DRX hardly occurred. This effect can be attributed to different DRX mechanisms that take place as a function of strain rate. At low strain rates, DRX occurred locally at the grain boundaries of the original microstructure, forming a so-called necklace structure. Increasing strain rate results in an increased fraction of recrystallized grains from 18% (0.1 s-1) to 39% (10 s-1). The microstructure revealed that twin boundaries act as nucleation sites for the DRX (TDRX). The recrystallized areas exhibit a weaker texture compared to the deformed microstructure.

Microstructure evolution and mechanical property of Mg-3Al alloys with addition of Ca and Gd during rolling and annealing process

Abstract The formability of magnesium alloys at ambient temperature can be enhanced by alloying additions such as Ca and RE elements, which is ascribed to the weakened basal texture. To produce magnesium alloy sheets with excellent comprehensive performance, the evolution of texture characterization during fabrication process and subsequent effect of texture on mechanical properties are vital controlling factors. In this investigation, three experimental Mg-3Al series alloys were hot rolled and annealed to sheets with 1 mm thickness. The microstructure evolution during rolling and annealing process was investigated. Furthermore, the influence of texture on tensile properties along different tensile directions was also studied. The results show that weakened basal texture and refined grains were achieved with the co-addition of Ca and RE element. However, strengthening of mechanical properties wasn't obtained. During hot rolling process, microstructure was refined, second phase particles broken, and basal texture was increased. While basal texture was weakened during annealing process. Recrystallization behavior influenced by formation of second phase was dominated to attenuate basal texture. Tensile deformation behavior was controlled by basal slip and followed Schmid factor criterion. Moreover, the weakened basal texture and activation of non-basal slips during hot rolling process can contribute to diminish the anisotropy of tensile properties.

Closed Die Forging of Mg-Al-Zn-Ca-Y Alloys

In light of emission reduction and weight saving in transport applications, Mg parts gain alot attention due to their good specific mechanical properties and their low mass. While casting is themain process for manufacturing Mg parts for automotive applications, forged parts show some majorbenefits like superior mechanical properties and absence of porosity. In this work a comparison ofclosed die forged parts made from different Mg-alloys has been carried out. The materials used in thewarm forging process were AZ31 and various Mg-Al-Zn-Ca-Y type (AZXW) alloys. Ca additions areknown to improve the oxidation behaviour and the formability of magnesium alloys, while yttrium isused to enhance the flammability resistance of forged parts. The forgeability, mechanical propertiesand microstructure are analyzed and compared in the present paper.

Developing a Zener–Hollomon Based Forming Limit Surface for Warm Sheet Forming of Magnesium Alloy

The concept of Zener–Hollomon (Z) based Forming Limit Surface (Z-FLS)—which has minor strain, major strain, and ln(Z) as its three axes—was initially proposed in a previous study. In the Z-FLS diagram, strain rate and temperature effects on the major limit strain are reflected by ln(Z). In the current study, the concept of Z-FLS is revisited to provide a practical approach to construct Z-FLS. A Z-FLS then is constructed for magnesium alloy AZ31B sheet material using available experimental forming limit curves. The constructed Z-FLS is used to identify fracture in a non-isothermal warm cup forming process, which was modeled as a coupled thermo-mechanical process. Based on the Z-FLS, the determined limiting draw ratio (LDR) matches well with the published experimental results.

Crystal plasticity modelling of shear band deformation and its effect on the formability of Mg–3Al–1Zn sheets

Shear bands is a kind of typical microstructure in magnesium alloy which has drawn much attention during recent years. The formation of shear bands during the isothermal differential speed rolling of Mg–3Al–1Zn sheets is analysed by experimental methods. In addition, results of Erichsen and tensile tests indicate that the shear bands have an obvious effect on the anisotropic fracture behaviour and formability of magnesium alloy. A represent volume element (RVE) method combined with crystal plasticity model is established to investigate the effect of shear bands on the anisotropic fracture behaviours systematically by considering the grain size, texture, width, and tilted angle. The simulation results disclose the above factors can induce discontinuous strain and stress between the shear band regions (SBRs) and non-shear band regions (NSBRs), but the grain size and tilted angle have much bigger effect than that of texture and width, leading to the fracture at the interface SBR and NSBR.

Evaluation of Friction Properties of Magnesium Alloy during Hot Forging by Ring Compression Test

This paper deals with friction properties and deformation resistance during hot forming of Mg-Al-Ca-Mn series magnesium alloys. Friction coefficients between dies and magnesium alloys were obtained by ring compression tests that used graphite, PTFE, and an oil lubricant in a hot-forging process. Hot forging was performed under various conditions to clarify the effects of types of lubricants and slide motion of the press machines on friction properties. Two types of slide motion, a constant velocity motion and a pulse motion were selected in the ring-compression test. It was found that graphite with an oil lubricant effectively eliminated die sticking in hot forming of magnesium alloys. The isothermal deformation resistances were derived using friction coefficients obtained by ring-compression tests as well as finite-element simulations. The predicted stress strain curves with temperature were examined with the stress-strain relationship obtained in experiments using a servo press and demonstrated the effectiveness of the proposed method.

Improved formability of magnesium alloy by repeated roll bending process

Improved formability of magnesium alloy by repeated roll bending process

Temperature Dependent Plastic Deformation Behavior of AZ31 Magnesium Alloy in Uniaxial and Biaxial Compressions

Metal forming of magnesium alloys often performed at elevated temperature, because magnesium alloys exhibit peculiar stress-strain relation and inferior ductility compared to conventional metals at room temperature. In the present study, deformation behavior and formability of cast and extruded AZ31 magnesium alloys under uniaxial and biaxial compressions at room temperature and at elevated temperatures were investigated. The results revealed that the compressive stress-strain relation of AZ31 magnesium alloy changed not only with the initial texture but also with the deformation temperature. The temperature dependency of flow stress of the cast alloy was smaller than that of the extruded alloy probably because of less influence of pre-deformation. In addition, the influence of compressive deformation pattern upon flow stress of the extruded alloy remained even at elevated temperature to 523 K. The temperature dependency of compressive fracture was also discussed and it was found that the equi-biaxial condition improved the compressive formability at elevated temperatures.

Forming of magnesium alloy by underwater shock wave

Abstract Magnesium alloys are best known for their light weight and high strength-to-weight ratio. In the forging process of magnesium alloys, hot working of has been often carried out. However, the strength of the material is reduced because the material temperature reaches the recrystallization temperature during hot working. Therefore, the cold method working is required to maintain or increase the strength of a material. In this study, we have designed experimental equipment to examine whether the forming of magnesium alloy is possible in the cold working by utilizing underwater shock wave, and the hardness of the material changes by receiving the underwater shock wave. Experimental results revealed increase in coefficient of extension and hardness of materials after receiving a shock wave.

Structure Analysis of Magnesium Alloy (AZ31) Wires at Different Stages of a Multistage Cold Drawing Process

The formability of magnesium alloys is the subject of efforts undertaken in many research centers due to their outstanding mechanical, plastic, and above all, physical properties. For this reason, magnesium alloys have become an important material which finds broad possibilities for application in many industries: automotive, electronics, aerospace and so on.The paper presents an analysis of changes in structure of AZ31 magnesium alloy wire cold-deformed in the drawing process using interoperate heat treatment. Microstructure observations of the wire by means of optical microscopy were performed in initial state, after each drawing process, and before and after heat treatment. The studies regarding the impact of selected variants of deformation on microstructure were also carried out at the scanning electron microscope (SEM).

Drawability Studies of Magnesium Alloy Sheets at Elevated Temperature / Badania Tłoczności Blach Ze Stopów Magnezu W Podwyższonej Temperaturze

Abstract The paper presents the results of a study of drawability of thin AZ31 magnesium alloy metal sheets. These studies are a continuation of experiences in presenting the characteristics of technological plasticity of strips made of magnesium alloy which have been cast between rolls in vertical and horizontal systems called ‘twin-roll casting’. In the context of previous experiments conducted at the Institute of Material Technology of the Silesian University of Technology in cooperation with the Technical University - Bergakademie Freiberg (Germany), drawability of these strips at elevated temperatures has been comprehensively defined while using forming limit curves. Due to low formability of magnesium alloys at ambient temperature, formability tests - including cup forming tests presented in this paper - have been carried out in heated dies at temperature range of 200°C to 350°C. A modern AutoGrid digital local strain analyzer has been used in the examinations and the method of image analysis of deformed coordination nets has been applied. Quantitative and qualitative impact of deformation temperature upon the drawability effects of AZ31 magnesium alloys products have been evaluated.

마그네슘 합금 판재를 활용한 차체 Reinforced Dash 부품 온간성형 공정 연구

The use of light weight magnesium alloy offers significant potential towards improvement of the automotive fuel efficiency. However, the application of formed magnesium alloy components in auto-body structures is restricted due to the low formability at room temperature and lack of knowledge for processing magnesium alloys at elevated temperatures. In this study, a warm tensile test of magnesium alloys was performed to measure tensile strength and elongation. An improvement in formability was confirmed at increased temperatures above about <TEX>$250^{\circ}C$</TEX>. Car body warm forming technology was conducted for forming forming reinforced dash components of the magnesium alloy AZ31B sheet at elevated temperatures.

Forming of magnesium alloy microtubes in the fabrication of biodegradable stents

Magnesium alloys have, in recent years, been recognized as highly promising biodegradable materials, especially for vascular stent applications. Forming of magnesium alloys into high-precision thin-wall tubes has however presented a technological barrier in the fabrication of vascular stents, because of the poor workability of magnesium at room temperature. In the present study, the forming processes, i.e., hot indirect extrusion and multi-pass cold drawing were used to fabricate seamless microtubes of a magnesium alloy. The magnesium alloy ZM21 was selected as a representative biomaterial for biodegradable stent applications. Microtubes with an outside diameter of 2.9mm and a wall thickness of 0.2mm were successfully produced at the fourth pass of cold drawing without inter-pass annealing. Dimensional evaluation showed that multi-pass cold drawing was effective in correcting dimensional non-uniformity arising from hot indirect extrusion. Examinations of the microstructures of microtubes revealed the generation of a large number of twins as a result of accumulated work hardening at the third and fourth passes of cold drawing, corresponding to the significantly raised forming forces. The work demonstrated the viability of the forming process route selected for the fabrication of biodegradable magnesium alloy microtubes.

Parameters Controlling High Temperature Deformability of Wrought Magnesium Alloys

Due to limited deformability at room temperature, high temperature forming of magnesium alloys appears as an interesting alternative. Superplastic properties can be obtained in the case of fine grained magnesium alloys and in this regime, due to significant damage sensitivity, fracture strain is mainly controlled by nucleation, growth and coalescence of cavities. Magnesium alloys with large grained alloys can also exhibit interesting deformabilities at high temperature since dislocation movements can be controlled by a solute drag effect promoting plastic stability. Examples of such situations are presented in the case of wrought magnesium alloys, the associated damage mechanisms being investigated thanks to 3D X-ray micro tomography performed in continuous mode, namely directly during high temperature deformation tests.

Potentials of Pulse Magnetic Forming and Joining

Magnetic pulse production methods such as forming, joining or separating demonstrate innovative high-speed processes. Such processes can be realized using a capacitor and an appropriate tool coil for forming and welding processes. The process strain rates, which can amount to 20,000 s-1, increase the formability of metallic materials significantly. Magnesium and aluminium alloys find a wider application in the automotive industry due to their light weight potential. Through the low density of these materials, the vehicle weight can be reduced considerably. Due to the hexagonal lattice of magnesium alloys industry-relevant deformation in metal forming processes can only be achieved in hot forming processes. The high-speed forming allows a significant increase of deformability of this alloy. The use of dissimilar metals in an assembly requires the development of innovative joining methods. Apart from being used form and force closure the magnetic pulse welding and adhesive bonding material with different partners is possible. Currently at the Institute for Machine Tools and Factory Management (IWF), TU Berlin, various research topics in the field of pulsed magnetic are investigated. The magnetic pulse sheet metal forming of magnesium alloys at room temperature is investigated in a basic research project. A defined demarcation of high-speed forming with respect to the quasi-static deformation is done by means of hardness measurements in the deformation zone. For this purpose a suitable experimental setup with different matrices is constructed. The experimental results of the pulse magnetic deformation are iteratively compared with simulation results. The aim is to develop a new material model which gives a precise prediction about the high-speed process. In the field of magnetic pulse welding, both basic research and industry-related research projects conducted at the IWF. The process requires an adapted tool coil geometry that meets the requirements of the weld geometry. Different coil geometries and weld geometries and possible applications are presented by way of example, the welding quality is quantified by means of different analytical methods. The material microstructure in the weld zone, characterized by light and scanning electron microscopy shows the typical features of a shock welded joint, as also observed in explosive welding.

A study of the hot and cold deformation of twin-roll cast magnesium alloy AZ31

Recent advances in twin-roll casting (TRC) technology of magnesium have demonstrated the feasibility of producing magnesium sheets in the range of widths needed for automotive applications. However, challenges in the areas of manufacturing, material processing and modelling need to be resolved in order to fully utilize magnesium alloys. Despite the limited formability of magnesium alloys at room temperature due to their hexagonal close-packed crystalline structure, studies have shown that the formability of magnesium alloys can be significantly improved by processing the material at elevated temperatures and by modifying their microstructure to increase ductility. Such improvements can potentially be achieved by processes such as superplastic forming along with manufacturing techniques such as TRC. In this work, we investigate the superplastic behaviour of twin-roll cast AZ31 through mechanical testing, microstructure characterization and computational modelling. Validated by the experimental results, a novel continuum dislocation dynamics-based constitutive model is developed and coupled with viscoplastic self-consistent model to simulate the deformation behaviour. The model integrates the main microstructural features such as dislocation densities, grain shape and grain orientations within a self-consistent viscoplasticity theory with internal variables. Simulations of the deformation process at room temperature show large activity of the basal and prismatic systems at the early stages of deformation and increasing activity of pyramidal systems due to twinning at the later stages. The predicted texture at room temperature is consistent with the experimental results. Using appropriate model parameters at high temperatures, the stress–strain relationship can be described accurately over the range of low strain rates.

A 3D Finite Element Simulation of Cold Roll Forming of Wrought Magnesium Alloy Sheets

In recent several years, although production of magnesium has risen dramatically, production of magnesium alloy sheet remains still at a very low level in practical use. The major barrier to greatly increased magnesium alloy use has been in still primarily high manufacturing cost as well as poor work ability of wrought magnesium sheet alloys. One of the author has investigated in cold roll forming of magnesium alloy, however detailed forming characteristics of the wrought magnesium alloy sheets has not been clarified. The aim of the study is to confirm possibilities of practical use of wrought magnesium alloy by using told roll forming process. A three dimensional elasto-plastic analysis by finite element method (FEM) has been conducted to examine the shapes of cross section, spring back characteristics, bending strains and longitudinal membrane strain of magnesium alloy sheet and cold rolled steel sheet during forming.