Search Results (278)

The VDA 238-100 tight radius bend test has gained widespread acceptance for plane strain fracture characterization of sheet metals in proportional loading without necking. The VDA test features a 60 × 60 mm² square blank with a 0.2 mm or 0.4 mm radius punch to provide plane strain bending where the fracture limit of the material is lowest. However, the through-thickness gradients that suppress necking and promote fracture on the convex surface in tension can be exploited to efficiently characterize the fracture strain from uniaxial to plane strain tension by varying the sample width. In this study, V-bend tests were conducted for various sample widths for four advanced high-strength steels: 980GEN3, DP1180, MP800-V1, and MP800-V2 with the local fracture strains measured using digital image correlation. Reducing the width-to-thickness ratio below five altered the stress state at the failure location, with an aspect ratio of one providing edge fractures under uniaxial tension. This aspect ratio was then applied to 980GEN3 and MP800 steel samples with punched edges as it provides an efficient method for sheared edge fracture characterization that is not susceptible to necking as with common sheared edge tensile tests. To mitigate strain averaging inherent in DIC near surfaces, a geometric-based arc length methodology was proposed. The sheared edge fracture limits from the V-bend tests were then compared with the results from conical hole expansion and in-plane bend tests. The sheared edge formability was observed to have a material-dependent sensitivity to the test method. MP800-V2, with centerline segregation, exhibited a pronounced sensitivity to the applied deformation mode with absolute differences in fracture strains of 0.13 while the MP800-V1 and 980GEN3 did not. Full article

In alignment with the European Union’s 2050 carbon-neutrality targets, the automotive industry is intensifying efforts to adopt lightweight materials that ensure structural integrity without compromising safety. Press-hardened steels (PHS), offering a combination of ultra-high strength and formability, are at the forefront of these developments. Standard PHS grades rely on Ti–B microalloying; however, further alloying with Nb and V has been proposed to enhance hydrogen embrittlement resistance via microstructural refinement and hydrogen trapping. This study investigates hydrogen transport and mechanical degradation in a Ti–Nb–V microalloyed PHS compared to a conventional Ti-only 22MnB5 grade. Electrochemical permeation, thermal desorption, and mechanical testing were employed to characterize hydrogen diffusivity, solubility, and trapping mechanisms. The Ti–Nb–V variant demonstrated lower hydrogen diffusivity, higher solubility, and improved resistance to delayed fracture, attributable to the presence of fine NbTiV precipitates. Full article

As the work hardening rate increases during the cold drawing of non-heat-treated steel (NHT steel), a significant loss in ductility and toughness can occur, leading to reduced formability and part quality. In this study, a bidirectional drawing process consisting of alternating forward and reverse passes is proposed to mitigate these issues and enhance the mechanical performance of the steel. Mechanical property evaluations, including tensile testing and three-point bending tests, were conducted to assess the effects of bidirectional drawing compared to conventional unidirectional drawing. The results showed that the bidirectionally drawn wire maintained a similar tensile strength to that of the unidirectionally drawn wire at a 70% area reduction, while exhibiting a 12% improvement in elongation. Microstructural analysis revealed grain refinement and reduced texture anisotropy in the bidirectionally drawn specimens, contributing to the observed enhancement in ductility. These findings indicate that bidirectional drawing is a promising approach for improving the formability and overall quality of high-strength, NHT steel components. Full article

For hot-rolled ferritic stainless steels with preferential α-fiber texture, the strong α-fiber texture is retained after annealing, greatly affecting the texture and plastic formability during the subsequent cold-rolling process. For optimizing the texture of hot-rolled steels toward the favorable γ-fiber type, it is essential to control the annealing temperature in the annealing process. To investigate the evolution of the microstructure, texture, and properties of hot-rolled ferritic stainless steel with preferential α-fiber orientation, a series of annealing tests was performed at the lab scale at 800, 840, 880, 910, 930, and 950 °C for 3 min. The microstructure, texture, and grain boundary characteristics of the tested samples were analyzed using optical microscopy (OM) and electron back-scattered diffraction (EBSD). The mechanical properties and plastic strain ratio (r-value) were determined through universal tensile testing. The results show that at temperatures above 840 °C, more than 93% of recrystallization occurs, leading to significant microstructural refinement. The α-fiber texture intensity typically diminishes with rising temperature, whereas the γ-fiber texture initially weakens during the early stages of recrystallization (below 840 °C) and subsequently exhibits a slight increase at higher temperatures. The improved formability of the material is mainly attributed to microstructural refinement and texture refinement, as reflected by the I(γ)/I(α) texture intensity ratio. At an annealing temperature of 930 °C, the I(γ)/I(α) ratio peaks at 0.85, static toughness is maximized, the strain-hardening exponent (n) reaches a high value of 0.28, and the maximum average plastic strain ratio ($\overline{r}$) is 0.96. This result represents the optimum balance between mechanical properties and formability, making it suitable for subsequent cold-rolling. Full article

Metal-composite joints, leveraging the high specific strength/stiffness and superior fatigue resistance of carbon fiber reinforced polymers (CFRP) alongside metallic materials’ excellent toughness and formability, have become prevalent in aerospace structures. Fastener flexibility serves as a critical parameter governing load distribution prediction and fatigue life assessment, where accurate quantification directly impacts structural reliability. Current approaches face limitations: experimental methods require extended testing cycles, numerical simulations exhibit computational inefficiency, and conventional machine learning (ML) models suffer from “black-box” characteristics that obscure mechanical principle alignment, hindering aerospace implementation. This study proposes an integrated framework combining numerical simulation with explainable ML for fastener flexibility analysis. Initially, finite element modeling (FEM) constructs a dataset encompassing geometric features, material properties, and flexibility values. Subsequently, a random forest (RF) prediction model is developed with five-fold cross-validation and residual analysis ensuring accuracy. SHapley Additive exPlanations (SHAP) methodology then quantifies input features’ marginal contributions to flexibility predictions, with results interpreted in conjunction with theoretical flexibility formulas to elucidate key parameter influence mechanisms. The approach achieves 0.99 R2 accuracy and 0.11 s computation time while resolving explainability challenges, identifying fastener diameter-to-plate thickness ratio as the dominant driver with negligible temperature/preload effects, thereby providing a validated efficient solution for aerospace joint optimization. Full article

Formability testing is a fundamental method for determining sheet metal’s susceptibility to deep drawing operations. This article presents the results of formability analysis of several batches of 0.7 mm thick cold-rolled DX56D+Z100-M-C-O steel sheets. As part of the preliminary tests, mechanical properties of the tested steel sheets were determined. The ARAMIS digital image correlation system was used to determine the formability of sheet metal during the hemispherical punch stretching test. The stretching tests were conducted over a wide range of strain rate variations between 2 mm/min and 17 mm/min. A total of 540 individual geometry measurements were taken to analyze the test material’s formability. It was observed that with increasing strain rate, the strength properties increased, while the plastic properties decreased. From the perspective of formability, the margin of plasticity (the ratio of yield strength to tensile strength) deteriorated with increasing strain rate in tensile tests. Forming limit curves revealed that at higher strain rates, the metal sheet’s formability decreased. A reduction in the safety margins with an increasing hemispherical punch stretching test speed was also observed. Full article

Based on hot-compression simulations combined with SEM and TEM analyses, the high-temperature deformation behavior and mechanisms of a new nickel-based powder superalloy FGH101 were investigated over 1020–1110 °C and strain rates of 0.001–0.05 s⁻¹. From the experimental data, the variations in the strain-rate sensitivity index m, the apparent activation energy for hot deformation Q, and the grain-size exponent p were determined as functions of strain rate and temperature. Hot deformation processing maps and mechanism maps incorporating dislocation density were established. The processing maps clearly revealed the evolution of formable regions at different temperatures and strains, while the mechanism maps successfully predicted the dislocation evolution and its operative hot deformation mechanisms by introducing the grain size evolution corrected by Burgers-vector compensation and the rheological flow stress behavior compensated by the modulus. The results indicated an optimal processing window of 1060–1100 °C at 0.001–0.003 s⁻¹. Within the tested regime, as the strain rate decreased, the operative mechanism for grain-boundary sliding transitioned from pipe-diffusion control to lattice-diffusion control. These findings provide a solid theoretical basis for the design and optimization of the isothermal forging process of the new FGH101 alloy. Full article

To address the technical challenge of balancing formability and strength in automotive aluminum alloys, this study examined an Al-4.35Mg-3.6Zn-0.2Cu alloy subjected to a combined heat-treatment schedule consisting of a two-step solution treatment (470 °C for 24 h followed by 460 °C for 30 min) and a subsequent two-step aging process (T4P: 80 °C for 12 h, followed by BH: 180 °C for 30 min). Microstructural evolution was characterized using transmission electron microscopy, and uniaxial tensile tests were performed in accordance with the GB/T 228.1-2021 standard at a strain rate of 0.2 mm/min. In the T4P condition, the matrix contained both GPI zones (~0.9 nm) and GPII zones (~1.2 nm), with no detectable T-phase precipitation. The presence of GPII zones enhanced ductility by promoting dynamic recovery after dislocation shearing, resulting in a yield strength (YS) of 178 MPa, an ultimate tensile strength (UTS) of 310 MPa, and an elongation (El) of 9%. After BH treatment, the GPII zones transformed into semi-coherent T′-Mg₃₂(AlZnCu)₄₉ precipitates (~2.4 nm), which strengthened the alloy through their semi-coherent interfaces. The retained GPII zones mitigated the loss of ductility, and the final mechanical properties reached a YS of 275 MPa, a UTS of 340 MPa, and an El of 8.5%, corresponding to a BH response of 97 MPa. Strengthening-mechanism calculations indicated that GP zones contributed approximately 120 MPa to the yield strength in the T4P state, whereas T′ precipitates contributed about 169.64 MPa after BH treatment. The calculated values agreed well with the experimental results, with a deviation of less than 3%. This study clarifies the precipitation sequence in the alloy—supersaturated solid solution → GPI zones → GPII zones → T′ phase—and establishes the relationship between microstructure and strength–ductility behavior. The findings provide theoretical guidance for the design and optimization of high-strength, high-formability aluminum alloys for automotive outer-panel applications. Full article

In this study, TiB₂/AlSi10Mg, 2 wt.% SiC + TiB₂/AlSi10Mg, and 5 wt.% SiC + TiB₂/AlSi10Mg composite powders were prepared via high-energy ball milling. For the first time, TiB₂ and SiC hybrid particle-reinforced aluminum matrix composites (AMCs) were fabricated using the Laser-Directed Energy Deposition (LDED) technique. The effects of processing parameters on the microstructure evolution and mechanical properties were systematically investigated. Using areal energy density as the main variable, the experiments combined microstructural characterization and mechanical testing to elucidate the underlying strengthening and failure mechanisms. The results indicate that both 2 wt.% and 5 wt.% SiC + TiB₂/AlSi10Mg composites exhibit excellent formability, achieving a relative density of 98.9%. However, the addition of 5 wt.% SiC leads to the formation of brittle Al₄C₃ and TiC phases within the matrix. Compared with the LDED-fabricated AlSi10Mg alloy, the tensile strength of the TiB₂/AlSi10Mg composite increased by 21.4%. In contrast, the tensile strengths of the 2 wt.% and 5 wt.% SiC + TiB₂/AlSi10Mg composites decreased by 3.7% and 2.6%, respectively, mainly due to SiC particle agglomeration and the consumption of TiB₂ particles caused by TiC formation. Nevertheless, their elastic moduli were enhanced by 9% and 16.3%, respectively. Fracture analysis revealed that the composites predominantly exhibited ductile fracture characteristics. However, pores larger than 10 μm and SiC/TiB₂ clusters acted as crack initiation sites, inducing stress concentration and promoting the propagation of secondary cracks. Full article

H1000 stainless steel is defined as a nickel-saving austenitic stainless steel, characterized by high strength and high elongation. DP590 steel is widely used in the manufacturing of vehicle bodies. DP590 dual-phase steel is classified as a high-strength low-alloy steel, known for its high strength and good formability. To address issues such as nugget deviation, inhomogeneous mixing of the internal nugget microstructure, and interfacial fracture during tensile-shear testing in resistance spot-welded joints of these dissimilar materials, a unilateral magnetic-assisted resistance spot-welding process was proposed. The influence of the external magnetic field on various properties of the joint was systematically investigated. The results indicate that the application of an external magnetic field significantly enhances the strength of H1000/DP590 dissimilar spot-welded joints, with joint strength increasing by approximately 14% and energy absorption capacity improving by about 30%. These improvements are attributed to the electromagnetic stirring effect induced by the magnetic field, through which the effective nugget diameter was enlarged, the microstructure was homogenized, and the macroscopic morphology of the nugget was modified. As a result, the bonding area between the nugget and the base metal is expanded, and the fracture mode of the joint is shifted from interfacial failure to partial button failure, thereby enhancing the mechanical properties of the joint. Full article

We report a scalable route to hybrid aluminum matrix composites (AMCs) based on Al6060 (as-fabricated condition) reinforced with 2 wt.% TiB₂ and 1 wt.% microsilica, fabricated by ultrasonically assisted stir casting (UASC) followed by radial-shear rolling (RSR). Premixing and preheating of powders combined with acoustic cavitation/streaming during UASC ensured uniform, non-sedimentary particle dispersion and low-defect cast billets. X-ray diffraction of the as-cast composite shows fcc-Al with weak TiB₂ reflections and no reaction products; microsilica remains amorphous. Electron microscopy and EBSD after RSR reveal full erasure of cast dendrites, fine equiaxed grains, weakened texture, and a high fraction of high-angle boundaries due to the concurrent action of particle-stimulated nucleation (micron-scale TiB₂) and Zener pinning/Orowan strengthening (50–350 nm microsilica). Mechanical testing shows that, in the cast state—comparing cast monolithic Al6060 to the cast hybrid-reinforced composite—yield strength (YS) increases from 61.7 to 77.2 MPa and ultimate tensile strength (UTS) from 103.4 to 130.7 MPa, without loss of ductility. After RSR to Ø16 mm (cumulated true strain ≈ 0.893), the hybrid attains YS 101.2 MPa, UTS 150.6 MPa, and elongation ≈ 22.0%, i.e., comparable strength to rolled Al6060 (UTS 145.1 MPa) while restoring/raising ductility by ~9.7 percentage points. Microhardness follows the same trend, increasing from 50.2 HV0.2 to 73.1 HV0.2 when comparing the base cast condition with the rolled hybrid. The route from UASC to RSR thus achieves a favorable mechanical strength–ductility balance using an economical, eco-friendly oxide/boride hybrid reinforcement, making it attractive for formable AMC bar and rod products. Full article

Lightweight magnesium alloys are gaining increasing attention as potential structural materials for automotive and aerospace applications due to their high specific strength and excellent recyclability. However, their formability and mechanical performance are often limited by strong basal texture and limited recrystallization during thermomechanical processing. In this context, the present study systematically investigates the effect of post-annealing treatment on the microstructural evolution, recrystallization behavior, and mechanical response of a hot-rolled Mg-3Al-1Zn-1Ca alloy. Detailed microstructural characterization revealed that Al₂Ca precipitates were uniformly distributed along grain boundaries in the as-received (AR) condition, where they contributed to significant pinning of boundary migration. Post-annealing treatment (350 °C, furnace cooling) resulted in non-uniform grain coarsening, driven by the interplay of precipitate pinning and differential stored strain energy, while also facilitating particle-stimulated nucleation (PSN) and recrystallization. Electron backscatter diffraction (EBSD) analysis confirmed a substantial increase in the fraction of high-angle grain boundaries and recrystallized grains in the heat-treated (HT) state, with kernel average misorientation (KAM) and grain orientation spread (GOS) analyses indicating pronounced recovery of lattice distortions. Mechanical testing demonstrated a significant decrease in yield strength (263 MPa to 187.4 MPa) and hardness (65.7 to 54.1 HV) due to dislocation annihilation and stress relaxation, while ultimate tensile strength remained nearly unchanged (~338 MPa) and ductility improved markedly (12.6% to 16.4%). These findings highlight the dual role of Al₂Ca precipitates in promoting recrystallization through PSN while simultaneously restricting excessive grain growth through Zener pinning. Full article

The effect of the chemical composition of two low-carbon steels, C18E and 22MnB5, on their behavior after forming by fine blanking was investigated. A specific tool, adaptable to a tensile testing machine, was designed to replicate an industrial half-cutting process. This tool allows for the production of samples with simple geometries and easy modification of the processing conditions. Residual elements in the raw material, concentrated in segregation bands, appear to play a key role in crack initiation within the shear zone during the blanking process. The role of non-metallic inclusions is discussed to explain the presence of large cracks in C18E, while 22MnB5 only shows damage nucleation. After fine blanking, a carbonitriding heat treatment process was performed to modify the initial microstructure and achieve the required mechanical properties in the final parts. Continuous cooling transformation diagrams were created for both steels to guide this process. The results of this study demonstrate the better formability of 22MnB5 by fine blanking, compared to that of C18E. Full article

This study investigates the machining deformation of thick aluminum alloy plates, specifically in aerospace frame components, focusing on the influence of asymmetric residual stress states and machining strategies. Aluminum alloys are commonly used for large structural components due to their strength, formability, and corrosion resistance. However, machining these components often leads to deformation caused by residual stress release, cutting forces, and thermal effects. Using finite element simulations and experimental validation, the study analyzes how asymmetric residual stresses, induced by spray quenching, affect deformation patterns during machining. It is found that lower initial stress asymmetry results in less deformation, while machining sequences that optimize stress release significantly reduce the final distortion. Among the strategies tested, the diagonal milling sequence yielded the smallest deformation, achieving a reduction of up to 4%. The study concludes that both the initial residual stress state and the machining strategy are critical in controlling deformation, offering insights for improving machining processes in aerospace manufacturing to enhance precision and reliability. Full article

The invasive Silver Carp (Hypophthalmichthys molitrix) in North America represents a promising resource for surimi production; however, its gel formability deteriorates significantly during frozen storage. This study investigated the deterioration of gel properties in Silver Carp surimi over six months of frozen storage, and showed that short-term frozen storage (<2 months) was beneficial for surimi gel-forming ability, while extended frozen storage (>2 months) tended to have detrimental effects. The adverse effect of long-term frozen storage could be mitigated via using food additives (e.g., manufactured microfiber, transglutaminase, and chicken skin collagen), among which transglutaminase was the most effective. Transglutaminase at a relatively low level (0.1 wt%) could effectively negate frozen storage’s effects, and produced surimi gel with quality attributes (e.g., gel strength, hardness, and chewiness) at levels comparable to those from fresh fish samples. To assess the effects of the addition of various food additives for quality improvement, a synthetic data-driven machine learning (SDDML) approach was developed. After testing multiple algorithms, the random forest model was shown to yield synthetic data points that represented experimental data characteristics the best (R² values of 0.871–0.889). It also produced improved predictions for gel quality attributes from control variables (i.e., additive levels) compared to using experimental data alone, showing the potential to overcome data scarcity issues when only limited experimental data are available for ML models. A synthetic dataset of 240 data points was shown to supplement the experimental dataset (60 points) well for assessment of the Frozen Silver Carp (FSC) surimi gel quality attributes. The SDDML method could be used to find optimal recipes for generating additive profiles to counteract the adverse effects of frozen storage and to improve surimi gel quality to upgrade underutilized invasive species to value-added food products. Full article