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Multi-directional forging of large-scale Mg-9Gd-3Y-2Zn-0.5Zr alloy guided by 3D processing maps and finite element analysis

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Abstract

The three-dimensional (3D) processing maps of cast Mg-9.0Gd-3.0Y-2.0Zn-0.5Zr alloy were established based on isothermal compression tests and dynamic material model (DMM). The stable and power-efficient forming domains were determined by considering both the instability and power dissipation efficiency maps. Multi-directional forging (MDF) was then simulated by employing finite element (FE) analysis in the Deform-3D software, using the 3D power dissipation efficiency maps as input. The optimal forging parameters were thus obtained for a large-scale ingot with 430 mm in diameter and 440 mm in height, i.e., a forging temperature of 450 °C and forging speed of 10 mm/s. Finally, a Mg-9.0Gd-3.0Y-2.0Zn-0.5Zr cake-shaped forged part with 900 mm in diameter and 100 mm in height was produced. After T6-heat treatment, the edge and center of the forged part exhibit homogeneous microstructure and relatively consistent properties, with the tensile strength, yield strength, and elongation being about 400 MPa, 320 MPa, and 14.0%, respectively. Using transmission electron microscopy, the main strengthening phases were revealed to be the dense nano-scale β′ phases that are uniformly distributed inside the material.

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All data are available from the corresponding authors on reasonable request.

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Funding

The authors gratefully acknowledge the supports of the National Key Research and Development Program of China (Grant No. 2021YFB3501002) and the National Natural Science Foundation of China (Grant No. 52071208).

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Authors and Affiliations

  1. National Engineering Research Center of Light Alloy Net Forming, School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai, 200240, China

    Jiyu Li, Shuai Dong, Chaoyu Zhao, Jian Zeng, Li Jin, Fenghua Wang, Fulin Wang & Jie Dong

Authors
  1. Jiyu Li
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  2. Shuai Dong
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  3. Chaoyu Zhao
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  4. Jian Zeng
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  5. Li Jin
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  6. Fenghua Wang
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  7. Fulin Wang
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  8. Jie Dong
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Contributions

Jiyu Li and Shuai Dong and Jian Zeng and Jie Dong conceived and designed the experiments, Jiyu Li performed the experiments and wrote the manuscript, Chaoyu Zhao performed the EBSD characterization, Jian Zeng and Li Jin and Fenghua Wang checked the data, and Jian Zeng and Fulin Wang proofread manuscript.

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Correspondence to Jian Zeng.

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Li, J., Dong, S., Zhao, C. et al. Multi-directional forging of large-scale Mg-9Gd-3Y-2Zn-0.5Zr alloy guided by 3D processing maps and finite element analysis. Int J Adv Manuf Technol 120, 5985–5996 (2022). https://doi.org/10.1007/s00170-022-09124-0

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  • DOI: https://doi.org/10.1007/s00170-022-09124-0

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