Optimizing Bendability and Hardness of Age-Hardenable Aluminum Sheets through Local Thermo-Mechanical Processing

Efe, Mert; Rader, Katherine E.; Overman, Nicole R.; Nasim, Wahaz; Ortiz, Angel; Soulami, Ayoub; Choi, Kyoo Sil

doi:10.1016/j.jmatprotec.2024.118709

Optimizing Bendability and Hardness of Age-Hardenable Aluminum Sheets through Local Thermo-Mechanical Processing

Journal Article · Fri Feb 28 04:00:00 EST 2025 · Journal of Materials Processing Technology

DOI:https://doi.org/10.1016/j.jmatprotec.2024.118709· OSTI ID:2564237

Efe, Mert ^[1]; Rader, Katherine E. ^[1]; Overman, Nicole R. ^[1]; Nasim, Wahaz ^[1]; Ortiz, Angel ^[1]; ^[1]; Choi, Kyoo Sil ^[1]

BATTELLE (PACIFIC NW LAB)

This paper introduces a novel thermo-mechanical process to modify the local mechanical properties of 6xxx aluminum (Al-Mg-Si-Cu) alloy sheets. In this process, two pairs of rollers travel along the length of a sheet while locally bending and unbending it so that the final shape and thickness of the sheet remains unchanged. Room temperature bending/unbending (B/U) produces a deformation gradient through thickness and local hardening in both T4 and T6 sheets (with 41% and 18% greater Vickers hardness, respectively). High temperature bending/unbending performed at ~ 500°C via induction heating, produces significant improvements in local formability as measured by bend testing. Formability levels equivalent to the as-received T4 temper are achieved within the processed zones of T6 sheets with bend angles of ~ 150°, without disturbing the T6 temper in the remainder of the sheet. Finite element simulations and characterization explained the mechanical property improvements and the heterogenous microstructure with weakened Cube texture. Due to its similarity with the roller hemming process, and its compact dimensions, the apparatus developed for B/U has the potential for seamless integration with roller hemming robots to selectively process high strength aluminum sheet materials within mass-production settings.

Research Organization:: Pacific Northwest National Laboratory (PNNL), Richland, WA (United States)

Sponsoring Organization:: USDOE

DOE Contract Number:: AC05-76RL01830

OSTI ID:: 2564237

Report Number(s):: PNNL-SA-197538

Journal Information:: Journal of Materials Processing Technology, Journal Name: Journal of Materials Processing Technology Journal Issue: _ Vol. 336

Country of Publication:: United States

Language:: English

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