Abstract:Using the flow stress curves obtained by Gleeble thermo-mechanical testing, the processing map of extruded magnesium alloy AZ31 was established to analyze the hot workability. Stress exponent and activation energy were calculated to characterize the deformation mechanism. Then, the effects of hot deformation parameters on deformation mechanism, microstructure evolution and hot workability of AZ31 alloy were discussed. With increasing deformation temperature, the operation of non-basal slip systems and full dev… Show more
“…In the compression experiment at 300 • C, when the strain rate increased from 0.001 to 1 s −1 , the volume fraction of DRX would be reduced sharply from 62 to 49.5% (Chen et al, 2018). The highly concentrated stress due to the difference in CRSS and inadequate development in DRX results in poor ductility of AZ31 alloy (Jin et al, 2017). According to numerical test result of four-stage SPIF, for AZ31B magnesium alloy sheet, the suitable feed rate is 250-350 mm/min, interlayer spacing is less than or equal to 0.8 mm, and tool diameter is bigger than 8 mm.…”
Magnesium alloys have many distinguished advantages; therefore, they are more and more popularly used in lightweight design of automotive and aviation manufacturing industries. However, its poor plasticity at room temperature has prevented its further application, especially in magnesium alloy sheet forming process. To expand the application of magnesium alloy sheets, single-point incremental forming process for rapid prototype manufacturing and small-scale productions of sheet metal was investigated. By combining finite element numerical simulations with physical experiments, the relationships between the maximum thickness differences and different process parameters are explored, and the optimal process parameters for forming a certain straight wall cylindrical part of AZ31 magnesium alloy were determined. Based on the analysis of the results, the formability of AZ31 magnesium alloy sheet using warm single-point incremental forming (SPIF) is improved with the increases of number of forming stage, forming temperature, and tool diameter but reduced with the increase of feed rate and interlayer spacing. The suitable forming temperature for AZ31 magnesium alloy sheet is about 250 • C. For forming the deeper straight wall cylindrical parts, at least four forming stages are needed.
“…In the compression experiment at 300 • C, when the strain rate increased from 0.001 to 1 s −1 , the volume fraction of DRX would be reduced sharply from 62 to 49.5% (Chen et al, 2018). The highly concentrated stress due to the difference in CRSS and inadequate development in DRX results in poor ductility of AZ31 alloy (Jin et al, 2017). According to numerical test result of four-stage SPIF, for AZ31B magnesium alloy sheet, the suitable feed rate is 250-350 mm/min, interlayer spacing is less than or equal to 0.8 mm, and tool diameter is bigger than 8 mm.…”
Magnesium alloys have many distinguished advantages; therefore, they are more and more popularly used in lightweight design of automotive and aviation manufacturing industries. However, its poor plasticity at room temperature has prevented its further application, especially in magnesium alloy sheet forming process. To expand the application of magnesium alloy sheets, single-point incremental forming process for rapid prototype manufacturing and small-scale productions of sheet metal was investigated. By combining finite element numerical simulations with physical experiments, the relationships between the maximum thickness differences and different process parameters are explored, and the optimal process parameters for forming a certain straight wall cylindrical part of AZ31 magnesium alloy were determined. Based on the analysis of the results, the formability of AZ31 magnesium alloy sheet using warm single-point incremental forming (SPIF) is improved with the increases of number of forming stage, forming temperature, and tool diameter but reduced with the increase of feed rate and interlayer spacing. The suitable forming temperature for AZ31 magnesium alloy sheet is about 250 • C. For forming the deeper straight wall cylindrical parts, at least four forming stages are needed.
“…For a certain strain and deformation temperature, the partial differential between J and G can be obtained by the strain-rate sensitivity index, m, as shown in Equation ( 11) [39]. The power dissipation map and the rheological instability map are two parts of the processing map.…”
Most near-β titanium alloy structural components should be plastically deformed at high temperatures. Inappropriate high-temperature deformed processes can lead to macro-defects and abnormally coarse grains. Ti-3Al-6Cr-5V-5Mo alloy is a near-β titanium alloy with the potential application. The available information on the high-temperature deformation behavior of the alloy is limited. To provide guidance for the actual hot working of the alloy, the flow stress behavior and processing map at α + β phase field and β phase field were studied, respectively. Based on the experimental data obtained from hot compressing simulations at the range of temperature from 700 °C to 820 °C and at the range of strain rate from 0.001 s−1 to 10 s−1, the constitutive models, as well as the processing map, were obtained. For the constitutive models at the α + β phase field and β phase field, the correlated coefficients between actual stress and predicted stress are 0.986 and 0.983, and the predictive mean relative errors are 2.7% and 4.1%. The verification of constitutive models demonstrates that constitutive equations can predict flow stress well. An instability region in the range of temperature from 700 °C to 780 °C and the range of strain rates from 0.08 s−1 to 10 s−1, as well as a suitable region for thermomechanical processing in the range of temperature from 790 °C to 800 °C and the range of strain rates from 0.001 s−1 to 0.007 s−1, was predicted by the processing map and confirmed by the hot-deformed microstructural verification. After the deformation at 790 °C/0.001s−1, the maximum number of dynamic recrystallization grains and the minimum average grain size of 17 μm were obtained, which is consistent with the high power-dissipation coefficient region predicted by the processing map.
“…Several studies have been published to estimate the optimum hot deformation performance of magnesium alloys and their composites, suggesting dynamic recrystallization (DRX) as a prevailing factor in deformation behavior at elevated temperatures due to the low stacking fault energy of magnesium alloys. [13][14][15][16][17] Jin et al 18 pointed out that DRX and activation of nonbasal slip systems as results of increasing temperature were the key reasons School of Mechanical Engineering, Iran University of Science and Technology, Tehran, Iran for enhancement in hot workability of AZ31 alloy. However, in the case of strain rate, they observed complicated results, showing that above 350 °C, the deformation mechanism was dislocation cross-slip, which favors DRX, while at low temperature (below 350 °C), the deformation mechanism was dependent on strain and strain rate, and insufficient DRX were detected, thus deteriorating the ductility of AZ31 alloy.…”
The hot deformation behavior of 2.5 wt.% submicron alumina reinforced magnesium composite manufactured by a new casting method was examined to assess the impact of extrusion ratio and initial microstructure on the hot workability of Mg/Al2O3 composite. The thermomechanical experiments were performed at strain rates from 0.001 s−1 to 0.05 s−1 and the temperature ranging from 523 K to 673 K. The processing map was developed using power dissipation efficiency in terms of temperature and strain rate. Results revealed that the higher extrusion ratio yields finer grain size and a more homogenous distribution of alumina particles resulting in lower flow stress and activation energy. Stable regions with more power efficiency (57%) and less instability were observed in materials that experienced higher strain. Based on the microstructural observation, dynamic recrystallization as the main restoration mechanism occurred at composite with a higher extrusion ratio and finer grains in all conditions. It was deduced that the enhanced workability of fine-grain material is confirmed by steady flow stress and safe zones of the processing map. It was also revealed that twinning–twinning intersection and flow localization are the main reasons for unstable flow in both samples with unlike grain sizes.
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