Material properties and formability of extruded Al‐Mg compounds as a function of temperature

Feuerhack, Andreas; Binotsch, Carolin; Awiszus, Birgit; Wolff, A.K.; Bramer, C R; Stockmann, Martin

doi:10.1002/mawe.201200007

Cited by 6 publications

(7 citation statements)

References 2 publications

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“…Macro and microscopic analyzes demonstrated that the final pieces did not present cracks or specific surface damage. This outcome aligns with those of FEUERHACK et al (2013), who investigated the axial and radial strain of Al-Mg bimetallic core bosses[23].The forming parameters did not lead to a metallurgical bond between the metals composing the bimetallic crosshead. However, the forged component exhibits rotational and axial interlocking due to metal flow.…”

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Numerical and Experimental Analysis of the Forging of a Bimetallic Crosshead

Rosiak,

Santos,

Alba

et al. 2023

Advances in Materials Science

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The automobile sector has been making increasing efforts to reduce the weight of automobiles, aiming at mitigating pollutant gas emissions. The use of innovative concepts, such as bimetallic components, has become attractive because it makes it possible to increase the strength-to-weight ratio of the components. In this study, the hot forging of a bimetallic crosshead is investigated. In the process, a billet with a cylindrical core of the magnesium alloy AZ61 is enclosed with a hollow cylinder of the aluminum alloy AA 6351 and forged at 400°C. The objective is to reconcile the low density of Mg alloys with the high corrosion resistance of Al alloys. In parallel, a finite element analysis of the process was carried out.

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confidence: 90%

“…Next, mesh convergence was performed to refine the selection of mesh parameters. 2013), who investigated the axial and radial strain of Al-Mg bimetallic core bosses [23].…”

Section: Methodsmentioning

confidence: 99%

Numerical and Experimental Analysis of the Forging of a Bimetallic Crosshead

Rosiak,

Santos,

Alba

et al. 2023

Advances in Materials Science

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“…The subproject B3 analyzes the production of Al-Mg compounds (AlMgSi1/AZ31) with the primary focus on the interface properties and the characterization of such kinds of compounds. Previous publications described the production process, the optimization steps for establishing flawless and completely bonded compounds as well as the simulation models for the numerical analyses and the prediction of the compound quality [2,3,4,5,6,7].…”

Section: Introductionmentioning

confidence: 99%

Formability of Hybrid Aluminum-Magnesium Compounds

Feuerhack

Binotsch

Awiszus

2013

KEM

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In the SFB 692 HALS (High-strength aluminum based lightweight materials for safety components), subproject B-3, the production of an aluminum magnesium compound by a hydrostatic co-extrusion process was investigated. The quality of these semi-finished products, especially the stability and robustness of the interface between the aluminum (AlMgSi1) sleeve and magnesium (AZ31) core, was of particular interest. Previous papers have described the first process optimization steps as the improvement of the die design as well as the numerical methods for identification of important process parameters and the development of a quality model for the interface. This paper describes the formability of such semi-finished products with subsequent forging processes, especially die forging. Therefore, two different die forging strategies were investigated. In the first approach the strand-shaped work piece, with a circular cross-section, was formed along its longitudinal axis with die forging. In the second approach the same geometry was radially formed with die forging. Thereby, the compound was formed in longitudinal direction up to an analytical equivalent strain value of 1.61 and in radial direction up to 1.38. First results showed that the interface of the aluminum magnesium compound is very stable and ductile enough to be forged. Dye penetration tests were performed to prove the stability of the interface in a first step. Then, micro sections were made to investigate the interface metallographically. No cracks or damages were detected with both test methods in the interface of the forged aluminum magnesium compound. Furthermore, numerical simulations were performed to analyze the forging processes in detail. Therefore, a full 3D simulation model was set-up with Forge2011 and the calibration was performed with the press force as well as the geometry aspects. The correlations between experiments and simulations are very well. By means of the calibrated simulation detailed analyses of interface section are performed and the stability of the interface was investigated. This shows that the compound quality reached by the hydrostatic co-extrusion process is very suitable for subsequent forming steps as die forging. The investigations show the potential of such hybrid compounds and clarify their application, especially in the automotive sector.

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“…Due to the use of DIC and a polynomial, such a point of discontinuity is not detectable in the presented investigation. However, smoothing does not change the sign, and because both materials exhibit similar stress strain curves at 300 °C , the dimension of the

h_{r r}

values is detected correctly. Therefore, the coefficient values of

h_{r r}

could be considered as uncritical because of the moderate interface strength .…”

Section: Resultsmentioning

confidence: 97%

Digital Image Correlation Used for Experimental Investigations of Al/Mg Compounds

Kirbach

Lehmann

Stockmann

et al. 2015

Strain

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Al/Mg compounds produced by hydrostatic extrusion exhibit unique characteristics in terms of high strength and low weight, which are required in lightweight safety parts. The compound interface between the core and sleeve is a brittle intermetallic phase consisting of Al 2 Mg 3 and Al 12 Mg 17 . However, a certain plastic deformability is required for subsequent processing of the semi-finished product by forming. To obtain a basic understanding of the deformation behaviour of the interface, the Digital Image Correlation is used together with a new analysis procedure based on the approximation of the displacement field with polynomial functions. The procedure is first tested with a bending test. The specimens exhibit a remarkable deformation behaviour under bending at high temperatures, which is confirmed by the results of radial upsetting tests. Even under a multi-axle load, the interface maintains a full material joint, though fragmentation occurs, and a new secondary interface between the fragments can be observed. In addition, an evaluation of light microscopy images and Eulerian Hencky strain values at the interface, which are based on the Digital Image Correlation results, imply a connection between the strain and the boundary layer's appearance.

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Material properties and formability of extruded Al‐Mg compounds as a function of temperature

Cited by 6 publications

References 2 publications

Numerical and Experimental Analysis of the Forging of a Bimetallic Crosshead

Numerical and Experimental Analysis of the Forging of a Bimetallic Crosshead

Formability of Hybrid Aluminum-Magnesium Compounds

Digital Image Correlation Used for Experimental Investigations of Al/Mg Compounds

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