Aluminum Alloys, Characterization and Processing: Formability and Simulation
Sponsored by: TMS Light Metals Division, TMS: Aluminum Committee
Program Organizers: Julie Levesque, Quebec Metallurgy Center; Stephan Broek, Kensington Technology Inc
Thursday 2:00 PM
March 23, 2023
Room: 32A
Location: SDCC
Session Chair: Julie Levesque, Quebec Metallurgy Center
2:00 PM
The Role of Microstructure on Strength and Fracture Anisotropy Effects in Al-Mg-Si Extrusion Alloys: Setareh Kordmir1; Nick Parson2; Warren Poole1; 1University of British Columbia; 2Rio Tinto Aluminium
Aluminum 6xxx extrusion alloys are attractive candidates for use in automotive applications to decrease vehicle weight. In this study, Al-Mg-Si alloys were extruded into 3 x 90mm strips on a pilot scale extrusion press with processing conditions designed to produce either a recrystallized or unrecrystallized microstructure. The grain shape and crystallographic texture were characterized by electron back scatter diffraction (EBSD) and mechanical anisotropy was measured by tensile and VDA bend testing conducted at 0, 45 and 90 degrees to the extrusion direction. It was found that strength and fracture anisotropy were significantly affected by crystallographic texture and the distribution of second phase particles. The results were rationalized using crystal plasticity (visco-plastic self consistent modelling) and considerations for the sequence of damage initiation, void growth and void coalescence.
2:25 PM
Comparison of Experimental Test and Finite Element Simulations of Car Crash Boxes which Manufactured with Different Aluminum Alloys: Melih Caylak1; Gorkem Ozcelik1; 1ASAS Aluminum
In consideration of developments in electric vehicle production, lightweight materials such as aluminum alloys have been started to use by Automotive Industry to diminish total weight of vehicles. Structural parts of automobiles such as car crash boxes require high impact damping energy and high tensile strength properties. To this end, different alloy compositions for aluminum alloys have been used to improve mechanical properties of metals.In this study, different aluminum alloys such as 6082 and 6005 has been considered as test materials and finite element (FE) simulations were carried out with LS-Dyna software. Crash boxes were manufactured with aluminum extrusion production method and subjected compression tests. In order to observe mechanical properties, tensile tests were performed according to extrusion direction. Results of FE simulations have been compared with experimental data. As a result of this study, it has been observed that similar FE results with real-time tests can be obtained.
2:50 PM
Exploring Semi-solid Deformation of Al-Cu Alloys by a Quantitative Comparison between Drained Die Compression Experiments and 3D Discrete Element Method Simulations: Te-Cheng Su1; Meng-Chun Chen1; Huai-Ren Hu1; Ying-Hsuan Ko1; Ling-En Yao1; 1Department of Materials Science and Engineering, National Taiwan University
Developing computational modeling for the semi-solid aluminum alloys with a solid network can help optimize advanced pressurized casting processes such as die-casting, squeeze casting, twin-roll casting, and semi-solid forging. However, a comprehensive numerical approach that can capture the coupled behavior between grain rearrangement and deformation of each individual grain remains a significant challenge. Inspired by recent synchrotron imaging work on deforming equiaxed-globular Al-Cu alloys showing granular deformation mechanisms, this research uses the 3D discrete element method (DEM) to generate two numerical assemblies of primary aluminum grains with volumetric solid fraction 0.52 and 0.82, respectively. Burger’s contact model is introduced to consider viscous interactions between two grains at high temperature. Contact model parameters are found by an iterative approach to reproduce the rheological response of drained die compression experiments. Validated 3D DEM simulations will be useful for exploring the relationship between deformation process parameters and strain localization of a bulk semi-solid.
3:15 PM
The Role of Through-thickness Variation of Texture and Grain Size on Bending Ductility of Al-Mg-Si Profiles: Philip Goik1; Andreas Schiffl2; Heinz Werner Höppel1; Mathias Göken1; 1Friedrich-Alexander-Universität Erlangen-Nürnberg; 2Hammerer Aluminium Industries Extrusion GmbH
Ductility and strength are often opposed properties in dislocation slip deforming materials, such as Al-Mg-Si wrought alloys. However, for safety parts in the mobility sector, high strengths and excellent ductility are required. While the strength of those alloys is governed by the precipitation state and density, the deformation behavior and ductility are affected by both precipitates and crystallographic texture. The deformation during extrusion leads to the formation of characteristic textures in the bulk, which are distinct to the plane strain deformation, and a peripheral coarse grain (PCG) layers beneath the surface. This PCG layer can have a detrimental effect on the bending ductility, which assesses the crashworthiness. However, an appropriate texture in the bulk can counteract the detrimental effect of PCG and increases the bending ductility at high strengths. Subsequently, based on EBSD investigations of bending deformed microstructures, a way to enhance bending deformation capability in Al-Mg-Si profiles is proposed.
3:40 PM Break
3:55 PM
Anisotropy of Tearing Behavior in AA7075-T6 Sheet at 200 °C: Daniel Nikolai1; Eric Taleff1; 1University of Texas Austin
The tearing resistance of AA7075-T6 sheet material was measured at room temperature and at 200 °C along different directions. Tearing resistance is characterized by the energy required to completely tear a specimen, with higher energies indicating greater tearing resistance. Specimens were ideally tested at 200 °C for times no longer than would provide a retrogression heat treatment, from which the full strength of the T6 condition may be recovered by a reaging heat treatment. Tearing resistance is significantly greater at 200 °C than at room temperature, which promises improved deformation processing of AA7075-T6. The tearing resistance at 200 °C varies with direction relative to the rolling direction. The tearing resistance is highest in the L-T orientation and lowest in the T-L orientation, by ASTM E871 specimen orientation designations. The significance of these results to the deformation processing of AA7075-T6 sheet at elevated temperatures will be discussed.
4:20 PM
Evaluating the Earing Amount of Materials Under Various Chemical Composition and Heat Treatment Process with Finite Element Simulations of Cup Drawing Tests: Melih Caylak1; Gorkem Ozcelik1; Abdullah Kinaci1; Koray Dündar1; 1ASAS Aluminum
In consideration of developments in electric vehicle production, lightweight materials such as aluminum alloys have been started to use by Automotive Industry to diminish total weight of vehicles. Structural parts of automobiles such as car crash boxes require high impact damping energy and high tensile strength properties. To this end, different alloy compositions for aluminum alloys have been used to improve mechanical properties of metals.In this study, different aluminum alloys such as 6082 and 6005 has been considered as test materials and finite element (FE) simulations were carried out with FE software. Crash boxes were manufactured with aluminum extrusion production method and subjected compression tests. In order to observe mechanical properties, tensile tests were performed according to extrusion direction. Results of FE simulations have been compared with experimental data. As a result of this study, it has been observed that similar FE results with real-time tests can be obtained.