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Developing bio-inspired functional surfaces on engineering metals is of extreme importance, involving different industrial sectors, like automotive or aeronautics. In particular, micro-embossing is one of the efficient and large-scale processes for manufacturing bio-inspired textures on metallic surfaces. However, this process faces some problems, such as filling defects and die breakage due to size effect, which restrict this technology for some components. Electrically assisted micro-forming has demonstrated the ability of reducing size effects, improving formability and decreasing flow stress, making it a promising hybrid process to control the filling quality of micro-scale features. This research focuses on the use of different current densities to perform embossed micro-channels of 7 μm and sharklet patterns of 10 μm in textured bulk metallic glass dies. These dies are prepared by thermoplastic forming based on the compression of photolithographic silicon molds. The results show that large areas of bio-inspired textures could be fabricated on magnesium alloy when current densities higher than 6 A/mm2 (threshold) are used. The optimal surface quality scenario is obtained for a current density of 13 A/mm2. Additionally, filling depth and depth–width ratio nonlinearly increases when higher current densities are used, where the temperature is a key parameter to control, keeping it below the temperature of the glass transition to avoid melting or an early breakage of the die. [ABSTRACT FROM AUTHOR]

The size effects in metal forming have been found to be crucial in micro-scale plastic deformation or micro-forming processes, which lead to attenuation of the material's formability due to the increasing heterogeneity of the plastic flow. The use of an electric field during micro-scale plastic deformation has shown to relieve size effects, enhance the material's formability, modify the microstructure, etc. Consequently, these electric-assisted (EA) micro-forming processes seem to bring many potential benefits that need to be investigated. Accordingly, here we investigated the influence of an electric field on the size effects to describe the fracture behavior in uniaxial micro-tension tests of an AZ31 alloy with various grain sizes. In order to decouple the thermal-mechanical and microstructure changes, room temperature (RT), oven-heated (OH), air-cooled (AC), and EA uniaxial micro-tension tests were conducted. The size effects contribution on the fracture stress and strain showed a similar trend in all the testing configurations. However, the smallest fracture stresses and the largest fracture strains were denoted in the EA configuration. EBSD examination shows that current-induced dynamic recrystallization (DRX) and texture evolution could be negligible under the studied conditions. The kernel average misorientation (KAM) maps give the larger plastic deformation in the EA specimens due to the reduction of plastic micro-heterogeneity. Finally, the fracture morphology indicates that the current-induced ductility enhancement may be attributed to the arrest of micro-crack propagation and the inhibition of void initiation, growth, and coalescence caused by lattice melting and expansion. [ABSTRACT FROM AUTHOR]