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Prediction for cryogenic formability of AA2219 alloy cylindrical parts with friction stir weld

  • Developments in modelling and simulation..Japan, South Korea and China
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Abstract

A cryogenic deep drawing process was proposed for complex curved surface part forming with aluminum alloy friction stir welded (FSW) blanks. The experimental forming limit curves (FLCs) of AA2219 alloy FSW blanks were obtained using the Nakajima tests at -196 °C. The theoretical FLC of base metal (BM) and weld zone for the FSW blank were calculated by M-K theory, respectively. The limited drawing ratio (LDR) was tested by the deep drawing of the hemispherical bottom cylindrical parts, and the splitting behavior of the drawn-part at ultra-low temperature was accurately predicted using the numerical simulations combined with theoretical FLCs. It was found that the forming limits and LDR of the FSW blanks were improved at -196 °C, and the FLD0 and LDR reached to 0.27 and 1.90, respectively. The improved cryogenic deep drawability was attributed to hyper hardening and high plasticity of the FSW blanks, which help to transfer deformation and prevent localized deformation from splitting in weak deformation zone. Finally, three effective methods were further proposed to improve cryogenic formability of FSW blanks. The increased blank holder force can ensure the suppressed co-existence of wrinkling and splitting due to increased resistance to localized deformation ability during cryogenic deep drawing. The strain distribution between the weld and BM zone of the deep drawn parts was more uniform by isothermal condition. Furthermore, the cryogenic formability can be further improved for the FSW blank with an offset weld.

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Abbreviations

\({f_0}\) :

Initial thickness unevenness

\(\bar {\varepsilon }\) :

Equivalent plastic strain

\({\varepsilon _{2b}}\) :

Minor strain of weaker zone

\({\sigma _{1b}}\) :

Major stress of weaker zone

Δɛ 1a :

Major strain increment of stronger zone

ρ :

Strain ratio

K :

Strength coefficient

r 0, r 45, r 90 :

Lankford coefficient

φ :

Effective stress increment divided by major stress increment

F, G, H, N :

Coefficient of Hill’s 1948 yield function

β :

Effective strain increment divided by major strain

\(\bar {\sigma }\) :

Equivalent stress

\({\varepsilon _{2a}}\) :

Minor strain of stronger zone

\({\sigma _{1a}}\) :

Major stress of stronger zone

\({\varepsilon _3}\) :

Normal strain

D 0 :

Initial blank diameter

α :

Stress ratio

n :

Strain hardening exponent

\(\bar {r}\) :

True plastic strain ratio

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Acknowledgements

This research was funded by the National Natural Science Foundation of China (No. 51875125) and the National Key Research and Development Program of China (No. 2019YFA0708801).

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Authors and Affiliations

  1. National Key Laboratory for Precision Hot Processing of Metals, Harbin Institute of Technology, 150001, Harbin, China

    Wei Liu, Yonggang Hao, Wen Sun & Mengjia Yao

  2. School of Materials Science and Engineering, Harbin Institute of Technology, 150001, Harbin, China

    Wei Liu, Yonggang Hao, Wen Sun & Mengjia Yao

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Liu, W., Hao, Y., Sun, W. et al. Prediction for cryogenic formability of AA2219 alloy cylindrical parts with friction stir weld. Int J Mater Form 16, 4 (2023). https://doi.org/10.1007/s12289-022-01724-1

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