The effect of microstructure on cavitation developed during hot deformation of a fine-grained AA5083 aluminum-magnesium alloy is investigated. Two-point correlation functions and three-dimensional (3-D) microstructure characterization reveal that cavitation depends strongly on the mechanism that controls plastic deformation. Grain-boundary-sliding (GBS) creep produces large, interconnected cavities rapidly during plastic straining. Solute-drag (SD) creep produces isolated cavities with less total volume fraction at a given strain. The 3-D microstructure data reveal adjacency between various microstructural features. Cavities are observed to be preferentially adjacent to large Al6(Mn,Fe) particles and to Mg-Si particles of all observed sizes. These data suggest that cavities preferentially nucleate at Mg-Si particles and at large Al6(Mn,Fe) particles. This result may be applied to reduce cavitation in commercial hot-forming operations utilizing aluminum-magnesium alloys.

https://link.springer.com/content/pdf/10.1007%2Fs11661-009-0061-5.pdf

Effect of Microstructure on Cavitation during Hot Deformation of a Fine-Grained Aluminum-Magnesium Alloy as Revealed through Three-Dimensional Characterization

The current available models describing superplastic deformation do not account for a number of important characteristics, leading to the current limited predictive capabilities of deformation and failure. In this work, the effects of cavitation and stress state on deformation stability during superplastic forming are investigated using Finite Element simulations. The simulations are performed using constant strain rate forming and using a proposed optimization approach based on a multiscale failure criterion that accounts for stress state, geometrical necking, and microstructural evolution including grain growth and cavitation. The simulations are conducted for the superplastic copper-based alloy Coronze-638 and the superplastic aluminum alloy Al-5083 which are known to develop significant cavitation during deformation. The results clearly show the importance of accounting for microstructural evolution during superplastic forming, especially when the state of stress is biaxial. Furthermore, the results highlight the effectiveness of the proposed optimization technique in reducing the forming time and maintaining the integrity of the formed parts.

The Effects of Stress State and Cavitation on Deformation Stability During Superplastic Forming

Jung-Kuei Chang, Ph.D. The University of Texas at Austin, 2008 Supervisor: Eric M. Taleff Aluminum alloys are of great interest to the automobile industry for vehicle mass reduction, which improves vehicle performance and reduces emissions. Hot forming processes, such as superplastic forming (SPF) and quick-plastic forming (QPF) have been developed to take advantage of the improved formability of certain aluminum materials at elevated temperature. Commercial fine-grained aluminum alloy AA5083 sheet is the most commonly used material in the SPF and QPF forming processes. Hot formability of AA5083 is often limited by material cavitation during forming, which makes understanding and controlling cavitation an issue of primary importance for improving hot sheet forming processes. The thermomechanical processing history of AA5083 can strongly affect superplastic performance, causing variations in formability between material lots. These variations are closely related to microstructure, and intermetallic particles are prime suspects for controlling cavitation behavior. However, there has been little more than anecdotal evidence available that these particles nucleate or influence

The effect of microstructure on cavitation during hot deformation in fine-grained AA5083 aluminum alloy sheet material

Effect of lubrication on deformation behaviour of a superplastic material has been given little attention, although it is important for industrial application. In this paper, a superplastic 5083 Al alloy under biaxial deformation was investigated by deforming the sheet into a cylindrical die cavity with and without lubrication. Several interrupted tests were performed to bulge the sheets to various depths for two different strain rates, the formed parts were then utilised to evaluate the effect of lubrication on metal flow, thickness distribution and cavitation. It was found that reducing the interfacial friction by use of a lubricant improved the metal flow after the deformed sheet had made contact with the bottom surface of die. Changes of the metal flow during forming not only developed a better thickness distribution of the formed part, but also reduced cavitation levels.

Deformation behaviour in superplastic 5083 Al alloy during biaxial gas pressure forming with lubrication

Multi-scale Modeling of Deformation and Failure Mechanisms of Al Alloys at Elevated Temperature

In this paper we address the controversial issue of nucleation of cavities in Al 5083 alloys and their subsequent growth to coalescence and failure. We focus on the origin and growth of cavities not only during the primary processing of Al 5083 in sheet forms, but also during the manufacture of these sheets into SPF (superplastic forming) components. Experimental observations of pre-existing cavities in this alloy are made using optical and electron microscopy. The role of sheet rolling direction, and the state of stress during superplastic deformation on the cavity formation and coalescence are also discussed. The effect of the state of stress (uniaxial, plane strain, balanced biaxial, and tri-axial) on the growth characteristics of cavitation is also examined. It is found that the uniaxial model based cavitation cannot directly be extended to predict the behavior of more complex stress states, unless great care is taken to identify the right strain measure for the mapping process.

Effect of State of Stress on the Cavitation Behavior of Al 5083 Superplastic Material

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Effect of State of Stress on the Cavitation Behavior of Al 5083 Superplastic Material