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Integrated Approach to the Superplastic Forming of Magnesium Alloys

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Integrated Approach to the Superplastic Forming of Magnesium Alloys University of Kentucky UKnowledge University of Kentucky Doctoral Dissertations Graduate School 2007 INTEGRATED APPROACH TO THE SUPERPLASTIC FORMING OF MAGNESIUM ALLOYS Fadi K. Abu-Farha University of Kentucky, [email protected] Right click to open a feedback form in a new tab to let us know how this document benefits ou.y Recommended Citation Abu-Farha, Fadi K., "INTEGRATED APPROACH TO THE SUPERPLASTIC FORMING OF MAGNESIUM ALLOYS" (2007). University of Kentucky Doctoral Dissertations. 493. https://uknowledge.uky.edu/gradschool_diss/493 This Dissertation is brought to you for free and open access by the Graduate School at UKnowledge. It has been accepted for inclusion in University of Kentucky Doctoral Dissertations by an authorized administrator of UKnowledge. For more information, please contact [email protected]. ABSTRACT OF DISSERTATION Fadi K. Abu-Farha The Graduate School University of Kentucky 2007 1 INTEGRATED APPROACH TO THE SUPERPLASTIC FORMING OF MAGNESIUM ALLOYS ABSTRACT OF DISSERTATION A dissertation submitted in partial fulfilment of the requirements for the degree of Doctor of Philosophy in the College of Engineering at the University of Kentucky By Fadi K. Abu-Farha Director: Dr. Marwan K. Khraisheh, Professor of Mechanical Engineering 2007 Copyright © Fadi K. Abu-Farha 2007 2 ABSTRACT OF DISSERTATION INTEGRATED APPROACH TO THE SUPERPLASTIC FORMING OF MAGNESIUM ALLOYS The economical and environmental issues associated with fossil fuels have been urging the automotive industry to cut the fuel consumption and exhaust emission levels, mainly by reducing the weight of vehicles. However, customers’ increasing demands for safer, more powerful and luxurious vehicles have been adding more weight to the various categories of vehicles, even the smallest ones. Leading car manufacturers have shown that significant weight reduction, yet satisfying the growing demands of customers, would not be feasible without the extensive use of lightweight materials. Magnesium is the lightest constructional metal on earth, offering a great potential for weight-savings. However, magnesium and its alloys exhibit inferior ductility at low temperatures, limiting their practical sheet metal applications. Interestingly, some magnesium alloys exhibit superplastic behaviour at elevated temperatures; mirrored by the extraordinarily large ductility, surpassing that of conventional steels and aluminium alloys. Superplastic forming technique is the process used to form materials of such nature, having the ability to deliver highly- profiled, yet very uniform sheet-metal products, in one single stage. Despite the several attractions, the technique is not widely-used because of a number of issues and obstacles. This study aims at advancing the superplastic forming technique, and offering it as an efficient process for broader utilisation of magnesium alloys for sheet metal applications. The focus is primarily directed to the AZ31 magnesium alloy, since it is commercially available in sheet form, possesses good mechanical properties and high strength/weight ratio. A general multi-axial anisotropic microstructure-based constitutive model that describes the deformation behaviour during superplastic forming is first developed. To calibrate the model for the AZ31 magnesium alloy, systematic uniaxial and biaxial stretching tests are carried out over wide-ranging conditions, using 3 specially-designed fixtures. In a collaborative effort thereafter, the calibrated constitutive model is fed into a FE code in conjunction with a stability criterion, in order to accurately simulate, control and ultimately optimise the superplastic forming process. Special pneumatic bulge forming setup is used to validate some proposed optimisation schemes, by forming sheets into dies of various geometries. Finally, the material’s post-superplastic-forming properties are investigated systematically, based on geometrical, mechanical and microstructural measures. KEYWORDS: Superplastic Forming of the AZ31 Magnesium Alloy, Constitutive Modelling, Elevated Temperature Mechanical Testing, Pneumatic Bulge Forming, Post-Forming Analysis Fadi K. Abu-Farha 15th May, 2007 4 INTEGRATED APPROACH TO THE SUPERPLASTIC FORMING OF MAGNESIUM ALLOYS By Fadi K. Abu-Farha Dr. Marwan Khraisheh Director of Dissertation Dr. Scott Stephens Director of Graduate Studies 15th May, 2007 5 RULES FOR THE USE OF DISSERTATION Unpublished dissertations submitted for the Doctor’s degree and deposited in the University of Kentucky Library are as a rule open for inspection, but are to be used only with due regard to the rights of the authors. Bibliographical references may be noted, but quotations or summaries of parts may be published only with the permission of the author, and with the usual scholarly acknowledgments. Extensive copying or publication of the dissertation in whole or in part also requires the consent of the Dean of the Graduate School of the University of Kentucky. A library that borrows this dissertation for use by its patrons is expected to secure the signature of each user. Name Date 6 DISSERTATION Fadi K. Abu-Farha The Graduate School University of Kentucky 2007 7 INTEGRATED APPROACH TO THE SUPERPLASTIC FORMING OF MAGNESIUM ALLOYS DISSERTATION A dissertation submitted in partial fulfilment of the requirements for the degree of Doctor of Philosophy in the College of Engineering at the University of Kentucky By Fadi K. Abu-Farha Director: Dr. Marwan K. Khraisheh, Professor of Mechanical Engineering 2007 Copyright © Fadi K. Abu-Farha 2007 8 Dedicated To: My beloved family; for the years of patience & support Those who have influenced my life; Rurouni, Simone, Wagner & Marwan Khraisheh The United States of America; for offering me this magnificent opportunity, & for the enormous kindness of its people Germany; the unsurpassed motivation of my life 9 ACKNOWLEDGEMENTS I would like to express my gratitude to all who have assisted me, in anyway, in accomplishing this work: My advisor, Dr. Marwan Khraisheh; for the enormous help, support, guidance, patience and encouragement throughout those five years, and without whom this work would not be what it is. RJ Robinson, and his team; who did not spare any effort in assisting me, in every possible way. Larry crocket, Richard Anderson and Mark Smith; who have machined hundreds of parts and thousands of test specimens. Mohammad Nazzal; for the collaborative effort in some parts of this work. Nathir Rawashdeh; for his assistance in building some of the experimental setups. Daniel Bortz; who instructed and assisted me in the microstructural examination. Center for Manufacturing staff, for their assistance, support, courtesy and kindness. To you all; I cannot thank you enough. iii TABLE OF CONTENTS TABLE OF CONTENTS.....................................................................................iv LIST OF TABLES….........................................................................................viii LIST OF FIGURES ............................................................................................ix CHAPTER ONE: PREFACE .............................................................................. 1 1.1 Problem Definition....................................................................................... 1 1.2 Motivations.................................................................................................. 2 1.2.1 Modelling Issues................................................................................... 2 1.2.2 Material Formability Issues................................................................... 3 1.2.3 Testing Issues ...................................................................................... 3 1.2.4 Forming Issues..................................................................................... 4 1.2.5 Post-Forming Issues............................................................................. 4 1.3 Objective and Methodology......................................................................... 4 1.4 Dissertation Layout ..................................................................................... 6 CHAPTER TWO: INTRODUCTION................................................................... 8 2.1 Superplasticity and Superplastic Forming Technique ................................. 8 2.1.1 Definition and Historical Overview........................................................ 8 2.1.2 Requirements for Superplasticity.......................................................... 9 2.1.3 Mechanical Aspects of Superplastic Deformation .............................. 10 2.1.4 Superplastic Materials ........................................................................ 12 2.1.5 Superplastic Forming Technique (SPF).............................................. 12 2.1.6 Current Applications of SPF ............................................................... 14 2.2 Light Weighting ......................................................................................... 17 2.3 Magnesium ............................................................................................... 19 2.3.1 General Overview............................................................................... 19 2.3.2 Magnesium’s History in the Automotive Industry................................ 20 2.3.3 Advantages ........................................................................................ 21 2.3.4 Problems and Limitations ..................................................................
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