Warm Forming Research Articles

Parasites in a Changing World: Troublesome or in Trouble?

There are plenty of reasons to believe that parasite populations will respond to biodiversity loss, warming, pollution, and other forms of global change. But will global change enhance transmission, increasing the incidence of troublesome parasites that put people, livestock, and wildlife at risk? Or will parasite populations decline in abundance-or even become extinct-suggesting trouble on the horizon for parasite biodiversity? Here, I explain why answers have thus far eluded us and suggest new lines of research that would advance the field. Data collected to date suggest that parasites can respond to global change with increases or decreases in abundance, depending on the driver and the parasite. The future will certainly bring outbreaks of some parasites, and these should be addressed to protect human and ecosystem health. But troublesome parasites should not consume all of our research effort, because this changing world contains many parasite species that are in trouble.

Comparative assessment of warm formability in Al–Mg alloys through limiting dome height experiments and finite element simulation studies

Comparative assessment of warm formability in Al–Mg alloys through limiting dome height experiments and finite element simulation studies

Formability Characterization Using Curvature and Strain-Rate-Based Limit Strain Detection Methods Applied to Marciniak, Nakazima, and Stretch-Bend Tests

Despite advancements in the characterization of forming limit curves (FLCs) with the development of stereoscopic digital image correlation (DIC), there is still uncertainty in the accuracy of the limit strains, especially in forming operations with out-of-plane bending. The ISO12004-2:2008 standard offers a standardized approach to FLC determination but is not without limitations and is not always applicable to new materials and forming processes (e.g., warm forming, hot stamping). In the present work, a physically based limit strain detection technique is developed, termed the Enhanced Curvature Method (ECM), based on the sheet surface curvature evolution at the onset of necking in sheet formability testing. The ECM is applied to the characterization of 1.1 mm AA5182-O sheet using Marciniak, Nakazima, and stretch–bend characterization tests, and its limit strains are compared with those from the linear best-fit (LBF) local strain-rate approach and the ISO-12004 standard. The ECM considers the physical nature of necking in sheet forming with the aid of thresholds defined in terms of an imperfection metric analogous to the well-known Marciniak–Kuczynski (MK) imperfection factor. By quantifying the evolution of necking, FLCs of different safety margins can be readily generated, enabling a more intuitive selection for the factor of safety. For lower and upper ECM thresholds, the Marciniak plane strain limiting strain was determined to lie between 0.173 and 0.198, respectively, which is comparable to the analytical prediction of 0.194 and in general agreement with the published literature for AA5182-O. Similar plane strain limits were obtained using the ISO and LBF methods with values of 0.188 and 0.208, respectively. The same rankings in limit strain values between methods were observed for plane strain loading in Nakazima and stretch–bend tests.

Deep Learning-Based Dust Detection on Solar Panels: A Low-Cost Sustainable Solution for Increased Solar Power Generation

The world is shifting towards renewable energy sources due to the harmful effects of fossils fuel-based power generation in the form of global warming and climate change. When it comes to renewable energy sources, solar-based power generation remains on top of the list as a clean and carbon cutting alternative to the fossil fuels. Naturally, the sites chosen for installing solar parks to generate electricity are the ones that get maximum solar radiance throughout the year. Consequently, such sites offer challenges for the solar panels such as increased temperature, humidity and high dust levels that negatively affect their power generation capability. In this work, we are more concerned with the detection of dust from the images of the solar panels so that the cleaning process can be done in time to avoid power loses due to dust accumulation on the surface of solar panels. To this end, we utilize state-of-art deep learning-based image classification models and evaluate them on a publicly available dataset to identify the one that gives maximum classification accuracy for dusty solar panel detection. We utilize pre-trained models of 20 deep learning models to encode the images that are then used to train and validate four variants of a support vector machine. Among the 20 models, we get the maximum classification of 86.79% when the images are encoded with the pre-trained model of DenseNet169 and then use these encodings with a linear SVM for image classification.

Study on warm formability of 2219 aluminum alloy with pre-deformation

Abstract The manufacturing process of launch vehicle storage tanks requires urgent simplification, which can be improved by forming the local features after artificial aging. Therefore, a new process of warm flanging aluminum alloys with pre-deformation was proposed to meet this requirement. The mechanical properties of 2219 aluminum alloy with pre-deformation were investigated at different temperatures using thermomechanical property testing. The deformation law of warm flanging was analyzed through simulation. The flanging limit of 2219 aluminum alloy with pre-deformation was obtained through experiments. Results showed that the ductility of 2219 aluminum alloy with pre-deformation increased then decreased with the increasing temperature, a maximum strain of 0.65 was obtained at 200°C. The equivalent strain gradually rose from the corner zone to the straight wall zone during flanging. The maximum equivalent strain is located at the edge of the straight wall, which gradually decreases with the increasing flanging coefficient. A flanging coefficient of 0.60 can be obtained at 200°C without splitting or seriously thinning. These results guide the local flanging of the integral bottom of 2219 aluminum alloy.

Assessment of aluminium alloys’ formability by elevated temperature testing

Abstract This work presents an investigation of the warm formability of AA7075-T6 aluminium alloy sheets using both experimental and numerical methods. Forming limit diagrams (FLDs) can be created by plotting the failure criteria on a graph with two axes representing major and minor strains. Sheets with a grid can be used to quantify both large and minor strains. General techniques available for the grid involve regular patterns of circles in this experiment. Experiments were conducted at various temperature levels, including room temperature, 100, 120, 140, 160, and 180 °C, as well as different strain rates. The investigation has revealed a significant impact of temperature on formability, while the effect of forming speed is quite insignificant across the whole range studied. At an ageing temperature of 140 °C, the distribution of precipitates is evenly balanced, resulting in improved mechanical strength. To offer accurate numerical models for warm-forming processes, a proposed constitutive model is introduced for aluminium alloy sheets. The present model incorporates plastic anisotropy and the effects of temperature and strain rate dependence. An investigation was conducted on the stress-strain behaviour of thin sheets composed of AA7075-T6 aluminium alloy under elevated temperatures and different strain rates. The objective was to ascertain the appropriate fitting parameters. It was associated with ABAQUS finite element modelling. The recommended material model was utilized to build finite element models, which were subsequently compared to the experimental data. The findings obtained from simulated isothermal uniaxial tensile tests were compared to the empirical measurements. The models used in the tensile test accurately predicted the material’s mechanical response. The predicted failure location, punch forces, and strain distributions for all three forming processes were found to be in close agreement with the experimental results. During deep draw operation, the warm forming limit curves were utilized to precisely predict both the pierce depth at which failure occurs and the precise location where the failure initiates.

Optimizing the Zn and Mg contents of Al–Zn–Mg wrought alloys for high strength and industrial-scale extrudability

High-strength Al alloys of the 7xxx series are promising candidates for further light-weighting of car bodies. However, they are difficult to process by extrusion: complex geometries in particular pose a major challenge due to high extrusion pressures and tool wear. In addition to process optimization, alloy chemistries can be tailored for properties such as good extrudability or high strength. In this work, several experimental alloys based on EN AW 7108A were investigated with respect to the contents of the main alloying elements Zn and Mg, as well as heat treatment (e.g., homogenization), to achieve good extrudability and favourable mechanical properties. The experimental alloys were initially extruded on a small-scale extrusion press and evaluated with regards to their warm formability, microstructure, extrudability, and mechanical properties in T5 temper. Alloy compositions with Mg contents <1.2 wt.-% are optimal and lead to good extrudability as well as high yield strengths well above 350 MPa. The Zn content, on the other hand, has minor influence on the extrudability, but significantly increases strength at higher contents (∼60 MPa). However, the combined Zn + Mg content should not exceed 7 wt.-%. Based on these findings, two optimized alloys were designed, direct chill cast on industrial scale, and extruded on an industrial extrusion press. The alloys showed good extrudability and high strength in the T5 condition. The results also reveal that the limits of the EN AW 7108A alloy are exhausted and higher strengths could only be achieved with the optimized EN AW 7003 alloy.

Novel Aging Warm-Forming Process of Al-Zn-Mg Aluminum Alloy Sheets and Influence of Precipitate Characteristics on Warm Formability

Concurrently improving the formability and post-formed strength of Al-Zn-Mg alloy sheets is crucial for producing high-strength parts with complex shapes. A novel process of aging warm-forming (AWF) to form solution heat-treated and water-quenched aluminum alloy sheets is proposed in this paper. The as-quenched AA 7075 sheet was first pre-aged and then formed at the desired temperature. The automotive paint–bake process was then utilized as the second aging step to achieve the target strength of the formed part. Additionally, the post-formed strength and warm formability of specimens under the AWF process conditions, as well as the warm-forming of various heat-treated Al-Zn-Mg alloy sheets proposed in previous studies, were compared through tensile and limit dome height tests. Precipitate characteristics of specimens subjected to different warm-forming process conditions were examined to understand their impact on warm formability. The warm formability of Al-Zn-Mg alloy sheets was significantly enhanced, and the post-formed strength achieved was more than 90% of the strength of as-received AA 7075-T6 sheets under the AWF process condition. The results demonstrated the feasibility of this novel AWF process to manufacture Al-Zn-Mg alloy stamped parts for improved spring-back, formability, and good overall post-formed strength. The results also indicate that microstructural characteristics in Al-Zn-Mg alloy sheets under different warm-forming process conditions have a noticeable influence on warm formability and final mechanical properties.

Research on the Dynamic Softening Mechanism of Dual‐Phase Structure During Warm Forming of Fe–8.5Mn–1.5Al Medium‐Manganese Steel

In this article, Fe–8.5Mn–1.5Al medium‐manganese steel is taken as the research object, and Gleeble 3500 thermal simulation testing machine is used to conduct isothermal compression at different deformation temperatures, strain rates, and strains in its austenite ferrite two‐phase zone. A constitutive model and a dynamic recrystallization volume fraction model for materials are established, and finite‐element method is used to simulate the temperature, equivalent strain, and dynamic recrystallization volume fraction distribution in different regions of the workpiece under different deformation conditions. By comparing and analyzing the microstructure, finite‐element simulation results, and hot working diagrams obtained from the experiment, the microscopic mechanism of dynamic softening of the material when ferrite and austenite coexist is explained; the transformation of the dynamic softening mechanism of the two phases with the hot deformation process is also explained. Early deformation mainly occurs in softer ferrite, which preferentially undergoes continuous dynamic recrystallization. Austenite has a lower stacking fault energy, and discontinuous dynamic recrystallization (DDRX) occurs when the dislocation density reaches a certain critical value. At the same time, when the strain reaches a certain level, the dynamic softening behavior of ferrite will also transform into DDRX. The optimal deformation conditions for Fe–8.5Mn–1.5Al medium‐manganese steel during warm processing in the two‐phase zone are a temperature of 720 °C, a strain rate of 0.01 s−1, and a large deformation zone.

Effect of forming parameters on the corrosion performance of retrogression- and warm-formed AA7075 alloy sheets

ABSTRACT Retrogression forming (RF) and warm forming (WF) are used to remedy formability limitations of high-strength precipitation-hardened AA7075 alloy sheets. RF is a thermomechanical treatment combining retrogression heat treatment and the forming of initially peak-aged T6 temper. WF is a thermomechanical treatment of initially pre-aged temper. The present work examines the corrosion performance of retrogression- and warm-formed AA7075 alloy sheets by determining the optimal pre-aging temperature (80°C or 100°C), forming temperature (room temperature, 150–200°C), strain rate (1, 0.1, or 0.01 s−1), and heating rate (1.1 or 20°C·s−1) for conventional slow and novel fast-forming technologies. Several alternating- and direct-current electrochemical tests were administered, including electrochemical impedance spectroscopy, potentiodynamic polarization, and linear polarization resistance. Results showed that the corrosion performance (i.e., passive film and corrosion-resistant properties) of formed AA7075 sheets was directly proportional to pre-aging and WF temperatures, inversely proportional to the RF temperature, and mildly affected by strain/forming rate and heating rate during forming.

Optimum heating time for warm forming of AA7075 aluminum alloy in T6 condition

Optimum heating time for warm forming of AA7075 aluminum alloy in T6 condition

Advanced FEM Insights into Pressure-Assisted Warm Single-Point Incremental Forming of Ti-6Al-4V Titanium Alloy Sheet Metal

This study employs the finite element (FE) method to analyze the Incremental Sheet Forming (ISF) process of Ti-6Al-4V titanium alloy. The numerical modeling of pressure-assisted warm forming of Ti-6Al-4V sheets with combined oil-heating and friction stir rotation-assisted heating of the workpiece is presented in this article. The thermo-mechanical FE-based numerical model took into account the characteristics of the mechanical properties of the sheet along with the temperature. The experimental conditions were replicated in FEM simulations conducted in Abaqus/Explicit, which incorporated boundary conditions and evaluated various mesh sizes for enhanced accuracy and efficiency. The simulation outcomes were compared with actual experimental results to validate the FE-based model’s predictive capacity. The maximum temperature of the tool measured using infrared camera was approximately 326 °C. Different mesh sizes were considered. The results of FEM modeling were experimentally validated based on axial forming force and thickness distribution measured using the ARGUS optical measuring system for non-contact acquisition of deformations. The greatest agreement between FEM results and the experimental result of the axial component of forming force was obtained for finite elements with a size of 1 mm. The maximum values of the axial component of forming force determined experimentally and numerically differ by approximately 8%. The variations of the forming force components and thickness distribution predicted by FEM are in good agreement with experimental measurements. The numerical model overestimated the wall thickness with an error of approximately 5%. By focusing on the heating techniques applied to Ti-6Al-4V titanium alloy sheet, this comparative analysis underlines the adaptability and precision of numerical analysis applied in modeling advanced manufacturing processes.

Impact of Drip Irrigation on Crop Growth, Yield, Water Productivity, and Weed Dynamics: A Review

The global water scenario indicates efficient water management practices are required to sustain agricultural productivity. The scarcity of groundwater resources is a global issue that is caused by increasing global population and climate change in the form of global warming. To alleviate the issue, the major water-consuming area implemented drip irrigation projects. It is recognized for its water-saving potential and gained prominence in crop cultivation. This study aimed to investigate the effect of drip irrigation on the growth, yield, water productivity, and weed dynamics of various crops. Results revealed that wheat under drip irrigation exhibited enhanced growth parameters, including increased plant height, leaf area index, and dry matter accumulation attributed to optimized soil moisture content. Drip irrigation significantly improved yield and yield attributes compared to traditional irrigation methods. Importantly, drip irrigation increased water productivity while reducing water use per unit of production. These findings highlight the potential of drip irrigation to reduce water shortages and increase crop output in the current global water context.

Damage evolution mechanism around AlN non-metallic inclusions in Fe-8.5Mn–3Al-0.2C lightweight medium-Mn steel during warm forming

Based on the tensile test in two-phase region, the damage evolution mechanism around AlN non-metallic inclusions in Fe-8.5Mn–3Al-0.2C lightweight medium-Mn steel during warm forming was elucidated. The findings indicate that voids primarily originate from the bonding interfaces between AlN non-metallic inclusions and ferrite. According to the numerical simulation results, strain eventually concentrates at the bonding interface where the AlN inclusion is connected to the high-strain ferrite in the direction parallel to the load, which is in good agreement with the experimental results. TEM analysis reveals the semi-coherent interface between AlN and austenite as well as the incoherent interface between AlN and ferrite. The incoherent interface between AlN and ferrite exhibits higher interfacial energy and worse mechanical stability, accelerating the separation of the bonding interface between AlN and ferrite.

Effects of different combinations of artificial ageing and warm forming on Ω phase and S phase evolutions in an Al-5.1Cu-1.0Mg-0.4Ag high strength aluminum alloy

Unlike common age-hardening materials, deformation prior to artificial ageing has been found to adversely affect the hardness of AA2040 aluminum alloy. To prevent this disadvantage, the effects of four different combinations of warm forming and artificial ageing at 200 °C on the microstructures and Vickers hardness of Al-5.1Cu-1.0Mg-0.4Ag aluminum alloy have been investigated. Among the four different combinations, the combination of 5% warm forming +1 h ageing yielded the lowest hardness value (154 HV), while that of 40 min ageing + 5% warm forming + 20 min ageing yielded the highest (169 HV). It is presumed that the proper timing of inducing dislocations by warm forming is decisive. The appropriate combination of warm forming and artificial ageing, i.e., 40 min + 5%+20 min treatment, produces a suitable amount of Ω phase during the first-stage ageing (40 min ageing), induces dislocations in the subsequent warm forming (5% deformation), and causes the significant amount of lath-like S phase to form on dislocations during the final-stage ageing (20 min ageing), thus enhancing the overall mechanical strength.

Green Accounting: Green Wasathiyah Campus

The issue of environmental change has become a hot topic to discuss in recent years due to climate change in the form of global warming caused by the industrial world. In addition to the industrial world, namely companies, one of the institutions affected by environmental changes is universities. Universities are now increasingly aware of the importance of preserving the environment in an effort to sustain it in the future, one of which is implemented by the State Islamic University (UIN) Salatiga. This research method uses descriptive qualitative analysis to determine the extent to which UIN Salatiga applies the concept of environmental accounting. From the results of the study, UIN Salatiga was ranked in the Top 6 PTKIN Green Campuses based on a ranking from the UI GreenMetric World University Rankings in 2021. Environmental Accounting has been applied by UIN Salatiga to detect environmental costs based on Hansen Mowen, environmental cost budgets based on the Green Campus UIN SalatigaThe drawback of UIN Salatiga in applying the concept of Environmental Accounting is that it has not recorded and has not been properly calculated regarding savings due to recording constraints.

Integrating reversion ageing and forming of high-strength Al alloys: Principles and theoretical basis

Simultaneously improving the formability and post-formed strength of high-strength aluminum (Al) alloys, such as Al–Zn–Mg–Cu alloys, is essential in manufacturing complex-shaped panel components. The strict requirements on heat-treatment condition and high tooling costs limit the applications of current forming methods. A novel process called integrated reversion ageing and forming (IRAF) is proposed to form naturally aged (NA or T4 tempered) Al alloys. A principle-based concept analysis and systematic thermo-mechanical-metallurgical study of the IRAF process were performed. Additionally, tensile tests were conducted to evaluate the effects of parameters including heating rate, holding time, and forming temperature on formability and baked strength. The deformability of the AA7075-T4 alloy can be significantly enhanced through rapid heating to the reversion ageing temperature (150–300 °C), followed by short-term holding, as evidenced by the reduced yield strength of 200 MPa and increased uniform ductility. An instant strength increase to a value close to that of the T6 state was obtained after a short bake hardening (BH) treatment. Further, temperature-time-property (TTP) diagrams were established based on the correlation between the measured mechanical properties and through-process microstructure evolution to explain the mechanism underlying the optimised processing window of IRAF. The results indicate that fast-heating rate (>300 °C/min) promotes the reversion of NA clusters and inhibits re-precipitation of solutes, thereby improving the warm formability. Reversion ageing above 240 °C could induce the formation of coarse η'/η phases, leading to a considerably declined BH response. To accurately predict the strength evolution and deformation behavior during IRAF, a physical-based unified constitutive model was constructed by considering the reversion of NA clusters and solute re-precipitation. The bending and drawing tests on the AA7075-T4 alloy sheets verified that IRAF in the most-reverted state enabled optimum formability. The findings inspire promoting the reversion of pre-existing metastable particles to improve warm formability and post-formed age hardening.

Corrosion and hardness properties of retrogression‐formed and warm‐formed AA7075 sheet

AbstractTo achieve combined formability and strength in high‐strength precipitation‐hardened aluminum automotive sheets, different forming path used with fast and slow forming technology has been proposed. This study reports hardness and corrosion properties from two elevated‐temperature forming techniques, retrogression forming (RF) and warm forming (WF), employed on AA7075 alloy sheets. Parameters such as optimal pre‐aging, re‐aging, WF, and RF temperature and time were determined. In the retrogression‐formed (R‐F) sheets, initial retrogression treatment of peak‐aged (i.e., T6) temper resulted in significant loss of properties, but final re‐aging step recovered most. When traditional peak‐aging treatment was used to re‐age R‐F sheets, their T6 hardness and corrosion properties were restored to 95%–97% and 86%, respectively, while re‐aging R‐F sheets using industrial post‐forming paint‐bake treatment restored their T6 hardness and corrosion properties to 87%–92% and 78%–79%. In the warm‐formed (W‐F) sheets, increasing pre‐aging temperature and time resulted in increasing properties, and properties of the best W‐F samples matched the R‐F samples. In addition, shorter‐time forming did not significantly reduce properties of formed part, encouraging the use fast‐forming technology. Overall, these findings show that sheets subjected to RF and WF techniques can possess T6 properties in formed parts.

Effect of Process Variables on Interface Friction Characteristics in Strip Drawing of AA 5182 Alloy and Its Formability in Warm Deep Drawing

Warm forming is widely used to enhance the formability of aluminum alloy sheets. In warm deep drawing, the process variables significantly affect frictional characteristics at the tool–blank interface. It has been a conventional approach to use a constant value of friction coefficients in the finite element (FE) simulations. However, this can occasionally result in suboptimal accuracy of the predictions. In the present work, strip drawing tests were carried out on AA5182 aluminum alloy sheets to investigate the effect of important process variables, namely, temperature, contact pressure, and drawing speed, on the friction coefficient in the warm forming temperature range (100–250 °C) under lubricated condition. The results obtained from the strip drawing tests were used for defining the friction conditions in the simulation of warm deep drawing of cylindrical cups incorporating the variation of the friction coefficient with contact pressure and speed at different temperatures. The Barlat89 yield criterion was used to define the effect of anisotropy in the material. The Voce hardening law and Cowper–Symonds model were used to incorporate the effect of strain hardening and strain rate, respectively, in the simulation. Drawability and peak force were compared with the predictions when a constant friction coefficient was assumed. Warm deep drawing experiments were conducted to validate the predicted drawability and load–displacement curves. It is clearly observed that the accuracy of prediction of the limiting drawing ratio and peak load through simulations is improved by incorporating the effect of pressure and speed on friction coefficient as it captures the local variations of friction during warm deep drawing precisely, rather than assuming a constant average friction coefficient at all the tool–blank contact areas.

Experimental heatwaves facilitate invasion and alter species interactions and composition in a tropical host-parasitoid community.

As mean temperatures increase and heatwaves become more frequent, species are expanding their distributions to colonise new habitats. The resulting novel species interactions will simultaneously shape the temperature-driven reorganization of resident communities. The interactive effects of climate change and climate change-facilitated invasion have rarely been studied in multi-trophic communities, and are likely to differ depending on the nature of the climatic driver (i.e., climate extremes or constant warming). We re-created under laboratory conditions a host-parasitoid community typical of high-elevation rainforest sites in Queensland, Australia, comprising four Drosophila species and two associated parasitoid species. We subjected these communities to an equivalent increase in average temperature in the form of periodic heatwaves or constant warming, in combination with an invasion treatment involving a novel host species from lower-elevation habitats. The two parasitoid species were sensitive to both warming and heatwaves, while the demographic responses of Drosophila species were highly idiosyncratic, reflecting the combined effects of thermal tolerance, parasitism, competition, and facilitation. After multiple generations, our heatwave treatment promoted the establishment of low-elevation species in upland communities. Invasion of the low-elevation species correlated negatively with the abundance of one of the parasitoid species, leading to cascading effects on its hosts and their competitors. Our study, therefore, reveals differing, sometimes contrasting, impacts of extreme temperatures and constant warming on community composition. It also highlights how the scale and direction of climate impacts could be further modified by invading species within a bi-trophic community network.