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Meeting 2026 TMS Annual Meeting & Exhibition
Symposium Forming and Joining of Advanced Sheet Metal Materials
Presentation Title 3D Microstructural Evolution of Automotive Sheet Aluminum Alloys After Thermo-Mechanical Processing
Author(s) Satyaroop Patnaik, Xiao-Xiang Yu, Eshan Ganju, Ankit Kumar, Minju Kang, Jaesuk (Jay) Park, DaeHoon Kang, Rajeev Kamat, John Carsley, Nikhilesh Chawla
On-Site Speaker (Planned) Satyaroop Patnaik
Abstract Scope High formability of high-strength automotive sheet aluminum alloys is crucial for preventing surface cracks and roughness during large deformations, such as bending. In this work, 3D x-ray microtomography, along with correlative microscopy, was employed to study the influence of forming on the microstructural evolution of two 6xxx series automotive sheet alloys. The microstructure was characterized by x-ray microcomputed tomography (XCT) to capture the degree of cracking and voiding in intermetallic particles. This was correlated to the particle composition, grain morphology, and substructures captured at various length scales. The mechanisms for microstructural evolution during processing will be discussed.
Proceedings Inclusion? Planned:
Keywords Aluminum, Characterization, Shaping and Forming

OTHER PAPERS PLANNED FOR THIS SYMPOSIUM

3D Microstructural Evolution of Automotive Sheet Aluminum Alloys After Thermo-Mechanical Processing
A Method for Friction-Based Optimization of the Ram Movement During Deep Drawing Aiming to Improve Part Quality
Achieving Superior Room Temperature Plasticity in High Strength 6xxx Aluminum Alloy
AI-Based Inverse Process Design for Shear Cutting of Advanced High-Strength Steels
Characterizing the Mechanical Properties of Solid State Diffusion Weldments With and Without an Interlayer Material
Development of an EoL Aluminum Twitch-Based Alloy for Automotive Applications
Development of Digital Image Correlation Test Procedures for Formability and Crash Material Cards
Enhancing Crashworthiness in Multistep Resistance Spot Welding of Advanced High-Strength Steel and 200 Series Austenitic Stainless Steel
Evolution of the Oxide Layer During Laser Sheet Metal Forming Aluminum Alloys
Experimental and Numerical Characterization of the Sheared Edge Fracture Limits in Multiphase Steels
Finite Element Modelling and Thermo-Microstructural Analysis of Friction Stir Welding of Aluminium and Steel Alloys
Hole Expansion Ratio of Ferritic 1 GPa Low Carbon Low Alloyed Steel
Improving Formability of a Ca-Bearing Magnesium Alloy With Warm Incremental Sheet Forming
In-Situ Measurement of Local and Global Springback in Single Point Incremental Forming
In-Space Laser Forming Simulated Under Thermal Vacuum Conditions
Increasing Post-Consumer Recycled Content in Steel Automotive Body Sheet: Examining Scrap Limits in the Electric Arc Furnace Using a Linear Optimization
Influence of Low-Temperature Thermal Cycling in Dissimilar Friction Stir Welding of Aluminium to Steel for Arctic Applications
Jetting–Oxide-Intermetallic Coupling and Electrical Performance of Al-Cu and Al-Cu-Cu Busbar Joints in VFAW
Lengthscale Transition from Coupons to Components: Direct Input of Optical Strain Data into Fracture Models
Machine Learning-Based Toolpath Compensation for Springback Control in DSIF
Mapping the Transition Between Bending Mechanisms for Laser Sheet Metal Forming
Multiscale Modeling of Incremental Sheet Forming Using Machine Learning of Crystal Plasticity
Novel, Energy-Efficient Spot-Welding Process Optimized for Dissimilar Joining of 6XXX-Series Aluminum to Advanced High Strength Steels
Optimization of MIG Welding Parameters for Aluminum Alloys in Automotive Applications
Performance and Weldability of Weld-Bonded 22MnB5 Steel: Simulation and Experimental Insights for the Automotive Industry
Physics-Based AI-assisted Design and Control of Metal Forming Processes
Post Weld Formability of Aluminum Alloys After Joining via Friction Stir Welding
Prediction of Sheared Edge Fracture Strain of DP980 Using U-Net Based Extraction of Edge Geometry
Process Development of Dissimilar Steel–Aluminum Friction Self-Piercing Riveting via Regression Analysis
Spot Weld Strategies to Improve the Weldability of Al-Si Coated Press Hardened Steel (PHS)
Sustainable Single-Step Friction Stir Processing for Grain Boundary Segregation and Functionally Graded Materials Development
Synergistic Role of High-Entropy Alloy Interlayer and Post-Weld Heat Treatment in Suppressing Intermetallic Compounds and Enhancing Joint Strength in Friction Stir Welding of Al-Fe Alloys
The Robocraftsman – Agile and Tool-Less Metal Forming With Robotics and Artificial Intelligence
Understanding Weld Nugget Formation in Ultrasonic Assisted Resistance Spot Welding (URW) Process

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