An Investigation of Hot Forming Quench Process for Aa6082 Aluminium Alloys
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IMPERIAL COLLEGE LONDON AN INVESTIGATION OF HOT FORMING QUENCH PROCESS FOR AA6082 ALUMINIUM ALLOYS A thesis submitted to Imperial College London for the degree of Doctor of Philosophy By MOHAMED SAAD KAMEL MOHAMED Department of Mechanical Engineering Imperial College London London SW7 2AZ 2010 Synopsis Synopsis This thesis is concerned with the mechanical properties and microstructure evolution during the novel solution Heat treatment Forming cold die Quenching (HFQ) process. HFQ is a hot sheet forming technology which incorporates the forming and quenching stages to produce high strength and high precision Al-alloy sheet parts. The work in the thesis divided into three main sections: Firstly, viscoplastic behaviour of AA6082 at different deformation temperatures and strain rates was identified through analysis of a programme of hot tensile tests. Based on the results from the hot tensile tests, a set of unified viscoplastic-damage constitutive equations was developed and determined for AA6082, providing a good agreement with the experimental results. SEM tests were carried out to investigate the damage nucleation and failure features of the AA6082 during hot forming process and the results are discussed. Secondly, the viscoplastic-damage constitutive equations were implemented into the commercial software ABAQUS via the user defined subroutine VUMAT for the forming process simulation. An experimental programme was designed and testing facilities were established for the validation of the FE process modelling results. A fairly good agreement between the process simulation and the experimental results was achieved. This confirms that the established FE process simulation model can be used for hot stamping of AA6082 panel parts. Further process modelling work was carried out to identify the optimal forming parameters for a simplified representation of a panel part. Finally, a precipitation hardening model was developed to predict the post-ageing strength of AA6082 panel parts, having varying amounts of forming-induced plastic strain. The model was tested against results of experiments which were carried out to 1 Synopsis investigate the effect of pre-deformation on the ageing kinetics of AA6082. The model is shown to fit and can be used to explain changes in the strength of the material. This set of equations was implemented in the VUMAT, in combination with the viscoplastic damage constitutive equation set, to model the whole HFQ process. The FE model was tested with experimental ageing and hardness results providing good agreements, which are discussed in light of the future development of the HFQ process. 2 Acknowledgements Acknowledgements I would like to express my gratitude to my supervisor Prof. Jianguo Lin for supervising my research and for his constant interest throughout the work and superb guidance and endless patience. His guidance, encouragement, and assistance have been a great help and I am indebted to him for providing the opportunity for me to develop the research presented in this dissertation. I wish to express my gratitude to Dr. Alistair Foster; he has always been available for suggestion and advice during several steps of the research. I thank also my colleagues in my office for their support, advice, and encouragement. I would like to express my thanking to my country Egypt for providing a scholarship for my PHD studies. A heartfelt thank to my wife, my daughter and my mother for their patience and support throughout my study in UK. 3 Table of Contents Table of Contents Synopsis ............................................................................................................................ 1 Acknowledgements .......................................................................................................... 3 Table of Contents ............................................................................................................. 4 List of Figures................................................................................................................... 9 List of Tables .................................................................................................................. 14 Nomenclature ................................................................................................................. 15 Chapter 1 Introduction .................................................................................................... 18 1.1 Automotive lightweight requirements .................................................................. 18 1.2 Forming of aluminium alloy panel components ................................................... 25 1.3 Introduction to the HFQ process ........................................................................... 28 1.4 Aims and structure of the thesis ............................................................................ 31 Chapter 2 Advanced Forming Techniques ..................................................................... 34 2.1 Introduction ........................................................................................................... 34 2.2 Manufacturing of lightweight components by metal forming .............................. 34 2.3 Advanced techniques for achieving high formability of materials ....................... 38 2.3.1 Superplastic forming (SPF) of sheet metal components ................................ 39 2.3.2 Hydroforming Process ................................................................................... 41 2.4 Development of hot stamping and cold die quenching processes ........................ 43 2.5 Microstructure control .......................................................................................... 46 2.6 Discussion and summary ...................................................................................... 50 Chapter 3 Experimental Programme .............................................................................. 52 3.1 Introduction and objectives ................................................................................... 52 3.2 Test material ......................................................................................................... 53 4 Table of Contents 3.3 Experimental programme of thermal and hardness tests for quenching rate effect .................................................................................................................................... 54 3.3.1 Sample preparation ......................................................................................... 55 3.3.2 Test facilities .................................................................................................. 56 3.3.2.1 Gleeble material simulator ...................................................................... 56 3.3.3 Test procedures .............................................................................................. 57 3.4 Experimental programme for ductility tests (hot tensile tests) ............................. 58 3.4.1 Test procedures .............................................................................................. 58 3.5 Strain ageing test for AA6082 .............................................................................. 60 3.5.1 Test procedures .............................................................................................. 60 3.6 Experimental programme for formability tests ..................................................... 61 3.6.1 Sample preparation ......................................................................................... 62 3.6.2 Test facilities .................................................................................................. 63 3.6.2.1 Hydraulic press and formability die sets ................................................. 63 3.6.3 Test procedures .............................................................................................. 65 Chapter 4 Experimental Results and discussions ........................................................... 67 4.1 Introduction ........................................................................................................... 67 4.2 Effect of the quenching rate on the mechanical properties of AA6082 alloys ..... 67 4.3 Effect of the high temperature deformation regime on the mechanical properties for AA6082 ................................................................................................................. 70 4.3.1 The effect of strain rate on the mechanical properties of AA6082 ................ 70 4.3.2 The effect of deformation temperature on the mechanical properties of AA6082 ................................................................................................................... 71 4.4 The effect of plastic deformation on the ageing kinetics prior to artificial ageing for AA6082 alloys ...................................................................................................... 73 5 Table of Contents 4.5 The effect of forming rate and drawing depth on the failure features and formability for AA6082 alloys ................................................................................... 74 4.6 Conclusions from the experimental results ........................................................... 76 Chapter 5 Development of Viscoplastic Damage Constitutive Equations ..................... 81 5.1 Introduction ........................................................................................................... 81 5.2 Deformation and damage mechanisms