characterisation - processing - manufacturing of lightweight materials _ fadi-clemson university

8/13/2019 Characterisation - Processing - Manufacturing of Lightweight Materials _ Fadi-Clemson University

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Characterisation Processing Manufacturing

ofLightweightMaterials

FadiAbu

Farha

AssistantProfessorofAutomotiveEngineering

Suite344CGEC

Office:(864)2837231

Mobile:(859)4892926

[email protected]


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MotivationsWhy

Lightweight

Materials?

Steel

is

still

dominant!

Greatweightsavingspotentials

Alotofchallengeshybridmaterials

Lightweightingisakeystrategyforreducingfuelconsumptionlevelsin

thetransportationsector

BMW5series

ALHSSs

AHSSs

CSs


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LightweightingResearch@CUICAROverall

Vision

MaterialCharacterisation

MaterialProcessing

Manufacturing

Goal:

GreaterUtilisationof

LightweightMaterials

in

the

TransportationSector

Methodology:

MaterialBased

Sustainable

ManufacturingOriented

IntegratedApproach

Understand,model

andpredict

material

behaviour

Modifyandoptimise

properties&structurefor

enhancedperformance

Improveprocesses

and

develop

new

techniques

LightweightStructures

Lightweight

Materials


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LightweightingResearch@CUICAROverall

Vision

MaterialCharacterisation

MaterialProcessing

Manufacturing

Goal:

GreaterUtilisationof

LightweightMaterials

in

the

TransportationSector

Methodology:

MaterialBased

Sustainable

ManufacturingOriented

IntegratedApproach

Understand,model

andpredict

material

behaviour

Modifyandoptimise

properties&structurefor

enhancedperformance

Improveprocesses

and

develop

new

techniques

LightweightStructures

Lightweight

Materials

AHSSteels

UHSSteels

Aluminium

Magnesium

CarbonFibreTitanium

?


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ResearchHighlightsMaterialCharacterisation


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MaindriveFormingtechniquesthatgohandinglovewithLWmaterials

GeneralMotors

MgAZ31B

AA5083

Warm/Hot Sheet FormingMagnesium, Aluminium and Titanium

1. WarmForming

2. QuickPlastic

Forming

[QPF]

(General

Motors)

3. SuperplasticForming[SPF](Boeing)

Mostoftheseprocessedrequirecharacteringmaterial

behaviouratextremeconditions(comparedtosteels).

Nostandardsinsomecases!


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GeneralMotorsSuperplasticandQuickplasticforming:

o Materialtestingandcharacterisation

o Constitutivemodelling

o Microstructuralexamination

o Processoptimisation

o Propertiesafterforming

o Frictionand

tribology*

Currentparts

Warm/Hot Sheet FormingMagnesium, Aluminium and Titanium

GeneralMotorsGeneralMotors

Formildsteels!

Optimisation!

Boeing


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Drive:DesignandOptimisationofHot

FormingofLightweightMetallicSheets

o Developedtesting

methodologies

for

lightweightmetallicmaterials.

o FromFormingLimitCurves(FLCs)

o ToFormingLimitSurfaces(FLS)

FLCs CompositeFLCs FLS

Lightweight Sheet Formability?At Extreme Conditions


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Drive:significantdifferencesin

performanceamongMgsheets!

Magnesium Sheets Production Issues!

Sheets

are

supplied

by

various

producers

A M

N O


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Drive:significantdifferencesin

performanceamongMgsheets!

FLCs

Magnesium Sheets Production Issues!

Post

forming

mechanical

properties Failure

Microstructuralexamination

Microstructure/Macrobehaviourrelationships


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ARAMIS5MfittedtoanINSTRON5985

loadframe

Tensile Testingwith DIC

ARAMIS5M


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Shownherearetheresultsofatensile

testonMgAZ31Bspecimen

Tensile TestResults


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ARAMIS5Musedtomonitorsheet

deformationduring

Nakajima

test

Biaxial Testingwith DIC

ARAMIS5M

BallPunch

Blankholder

Mirror


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WithDIC

Preliminary tests

Thisspecimenwasbulgedto~500psi


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ResearchHighlightsMaterial

Processing


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Steelisdominant.Andwillstaydominantforthenextdecade(atleast)

Ultra High Strength Steels03rd Gen. AHSSs

Wehaveachievedalotwithsteels.

Wearepushingformore:

higherstrength>1000MPa

Highductility>25%

Movingfrom01st Gen.

To03rd Gen.

USS


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Steelisdominant.Andwillstaydominantforthenextdecade(atleast)

Ultra High Strength Steels03rd Gen. AHSSs

Wehaveachievedalotwithsteels.

Wearepushingformore:

higherstrength>1000MPa

Highductility>25%

Movingfrom01st Gen.

To03rd Gen.

USS


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Drive:Forprocessing/formingbulklightweightmaterials

Fromfrictionstirwelding/processingofsheetstofrictionstirformingofbulkmaterial

Processingtoolmovesaxially!

Bulk Friction Stir FormingConcept

Bulk friction stir

forming (BFSF)


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Forprocessing/formingbulklightweightmaterials

Itcouldbeaviableprocessing/formingtechnique,particularlyforhardtodeform

materials.

such

as

magnesium

alloys.

Stirringheatsthematerial(tosoftenit),thus

Facilitatesductiledeformation

Bulk Friction Stir FormingWhy?

Bulk friction stir

forming (BFSF)


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Previous/CurrentWork

Thisform:FrictionStirBackExtrusion

Energyefficient

tube

forming

process

(Al

&

Mg)

Grainrefinementandothergreatpotentials!

Noneedforpostprocessheattreatment.

Bulk Friction Stir FormingFriction Stir Back Extrusion (FSBE)

AA6063


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Energyefficient

tube

forming

process

(Al

&

Mg)




AA6063


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Significantgrainrefinement

ForMagnesium:



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Challenges

ForMagnesium:

Bulk Friction Stir Forming

Friction Stir Back Extrusion (FSBE)


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Challenges

ForMagnesium:



AA6063

MgAZ31BF


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OneofseveralSPDtechniques;usedtoproduceultrafinegrainedmaterials.

Increasestrengthbygrainrefinement

Ithas

multiple

advantages

over

other

SPD

techniques

(fromapracticalpointofview):

Canproduceprocessedmaterialinbulksizes(sheets)

Usesatypicalrollingmill(nosubstantialadditionalcosts)

Outputsizeissimilartothestartingsize

Accumulative Roll Bonding

Grain Refinement for Strength Enhancement

ARBSchematic


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ProcessingCPTitoincreaseitsstrengthtolevelscomparabletothoseoftheTi6Al4V

WarmARB

processing

can

produce

same

grain

refinement

levels

of

cold

ARB

processing



CPTiARBprocessed@~450C


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Evolutionof

grain

geometry;

strength/grain

size

relationship




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Postprocessing

heat

treatment

could

increase

both

strength

and

ductility



ARB@400CPPT@250Cfor10min. ARB@450CPPT@450Cfor10min.


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ResearchHighlightsAdvanced

Manufacturing


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Energyefficient

tube

forming

process

(Al

&

Mg)





AA6063


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Energyefficient

tube

forming

process

(Al

&

Mg)





AA6063


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FutureWork

o Evenrecyclingscrapmetaldirectlyintoafinalproduct


Expand to Forging and Recycling


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Modify: ISR for Texture control

FutureWork

Isolatedshearrollingfortexturecontrol

Rollingwithout

bonding

Preliminaryresultsareencouraging!


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Modify: ISR for Texture control

FutureWork

Isolatedshearrollingfortexturecontrol

Rollingwithout

bonding

Preliminaryresultsareencouraging!


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GeneralMotors

Complexpartscanbeformedinonestep,

comparedtoconsolidatingmultipleparts

FromWarm/HotPneumaticSheetMetalForming

o SPF/QPF

TowardsmoreSustainableManufacturingConcepts

o Reverse/forwardforming

Reverse/Forward Sheet Forming

Cyclic Sheet FormingGeneralMotors


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o Basedonhotstampingofboronsteels(yetwithnomartensitictransformation!)

o EconomicyetfastproductionofMgandAlsheetcomponents

Hot Blank Cold Die Forming

For Magnesium and Aluminium Sheets


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Hot Blank Cold Die Forming

For Magnesium and Aluminium Sheets

PreliminarySetupandTesting

o Coolingcurves

o

Forming

window

for

aluminium

and

magnesium

is

big

enoughforHBCD


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WhatsNext

BMW5series

AHybridofdifferentmaterials

VolvoXC60

AudiA8(2010)

FutureisAdvanceandIntegrate

BMWi3


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WhatsNext

BMW5series

AHybridofdifferentmaterials

VolvoXC60

AudiA8(2010)

FutureisAdvanceandIntegrate

BMWi3


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Thank You !!!

characterisation - processing - manufacturing of lightweight materials _ fadi-clemson university

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