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The single-pulse laser hardening of a hypereutectoid steel coated by a graphite layer was investigated using a numerical/experimental approach. Experimental tests were conducted on coated samples using a fibre laser source and without any gas shielding aiming to explore the effect of laser power, pulse energy and defocusing distance on the dimensions of the hardened region. The process operating window of the discrete spot laser hardening using the graphite layer was determined through a finite element model and compared with previous results obtained on uncoated samples. For the same laser power and interaction times, an enlargement of the hardened region was found when using the graphite coating, especially when operating at the lowest laser energy level. The process operating window remains similar in shape to the one of the uncoated steel but moves towards larger hardened diameters and much larger defocusing distances. Once the maximum temperature has been fixed, a linear relationship between the hardened diameter and the defocusing distance exists. No obvious surface oxidation occurs since the graphite coating acts as a protective layer. [ABSTRACT FROM AUTHOR]

An experimental ternary magnesium alloy, Mg-2Zn-2Ce, has been investigated. The attention was focused on the possibility of using this alloy for an unconventional sheet-forming process based on a flexible medium (gas-forming) for applications where weight-saving and complex shapes are required. Free inflation tests were performed at temperatures ranging from 350°C to 450°C, employing either a constant forming gas pressure or pressure jumps during the same test in order to evaluate the strain rate sensitivity, m, of the material. Interrupted free inflation tests at known dome heights were also conducted to investigate both the strain and the microstructural evolution. In addition, the texture behavior of the alloy was studied after hot rolling, revealing a weak deformation texture. Even though the material was in the as-cast condition, the alloy showed a good deformation capacity and contribution due to grain boundary sliding, indicating a potential for superplastic deformation. [ABSTRACT FROM AUTHOR]

In this study, AZ31 sheets were subjected to gas forming using a stepped geometry die and employing two different temperatures (400°C and 450°C) and exposure times (60 s and 120 s). Microstructural examinations revealed that the density of the mechanical twins may be taken as indicative of the progress of recrystallization together with the relative grain size. Although gas forming was successfully applied, the severe residual texture inherited from the initial material was found to persist and was little affected by the operating conditions and the multiaxial stress state of the process. [ABSTRACT FROM AUTHOR]

In this work, the gas forming of AZ31 magnesium alloy 0.75-mm-thick sheets at elevated strain rates (fast gas forming) is investigated through an experimental-numerical approach. First, free inflation tests were carried out to find the conditions, in terms of temperature and forming pressure, able to give the best compromise between the alloy formability and the forming time. The analysis was successively moved to a closed die forming application with a stepped geometry case study in order to analyse the real forming process. Both an axisymmetric model of the free inflation test and a 3D model of the closed die forming process were built to correlate the results from free inflation tests (in terms of optimal strain rate values) to the closed die forming test: Numerical simulations were run to find the pressure value to be applied in gas forming tests. Experimental gas forming trials were finally conducted in order to support the approach and to analyse post-forming characteristics of the formed parts. Results showed that very small fillet radii can be reached on a commercial Mg alloy sheet setting very short forming times (few seconds). The choice of the forming temperature and of the corresponding optimal strain rate strongly affects the grain growth and the cavitation phenomena. Even if the alloy is prone to a strong static and dynamic grain growth at elevated temperatures, a small mean grain size value can be reached in the formed component due to the short forming times. [ABSTRACT FROM AUTHOR]

In this work, the effect of the laser-material interaction on the formability of a superplastic aluminum alloy was investigated. In applications such as Tailor-Welded Blanks and in the manufacturing of very large components with a complex shape, laser welding combined with superplastic forming may be a very fitting industrial tool. Bead on plate tests were carried out in order to simulate the laser-welding process and then, free inflation tests were performed to evaluate the compatibility of these two processing techniques. The Al-Mg alloy used in this work has a very small grain size which ensures the superplastic behavior. With the aim of preserving this peculiarity, the following aspects on the formability were investigated: (i) the surface condition of the bead before the forming test (with and without the removal of the excess of metal); (ii) the effect of the travel speed of the laser source on the mean grain size; (iii) the introduction of a refiner, commonly used in aluminum casts, in the molten pool in order to further reduce the mean grain size. [ABSTRACT FROM AUTHOR]

Numerical methods are widespread in forming applications since a deeper understanding and a finer calibration of the process can be reached without most of the assumptions used in analytical approaches. In this calibration procedure the characterization of the material behaviour is an important preliminary step that cannot be avoided. Experimental tests can be numerically modelled and material constants can be found by inverse methods making numerical results as close as possible to experimental ones. In this work material parameters of a superplastic aluminium alloy have been found by experimental forming tests and an inverse analysis. Constant pressure free inflation tests were firstly performed to find the optimal range for temperature and strain rate values. Material constants were then calculated, on the basis of these tests, minimizing errors between experimental and numerical data through a gradient based optimization iterative procedure. Constant strain rate experimental tests were finally used to refine material parameters and to gain a better agreement between experiments and numerical simulations. [ABSTRACT FROM AUTHOR]

In this work, the feasibility of reducing the cycle time in superplastic forming through a selective approach in the algorithm that calculates the forming pressure profile was investigated. First, a 3D numerical model of the blow forming process is created. Then, the blank was partitioned in different characteristic areas according to their strain and strain rate histories. Thus, different pressure profiles were numerically calculated choosing different combinations of those partitions of the blank. Experimental trials were finally carried out in order to explore the potential reduction of the forming time that can be achieved through the described approach without affecting the post-forming properties of the formed specimens. Post-forming properties were measured in terms of thickness distribution, mean grain size, and cavitation effects along the formed sheet. In particular, experiments were performed both with the conventional approach (with the whole sheet being monitored) and considering only the area of the sheet that experiences the highest strain values at the end of the forming process. Results highlighted that this latter approach can efficiently reduce the cycle time. [ABSTRACT FROM AUTHOR]

In this work, the mechanical and technological behaviour of AZ31 magnesium alloy laser welded joints is investigated. The forming behaviour of the joints is analysed by both tensile and biaxial stretch tests. Each test is monitored using a digital image correlation system in order to acquire the complete strain field during the whole test. Both in tensile and biaxial stretching tests, the strain maps reveal that the weld bead makes the strain path experienced by the welded specimen more critical than the one experienced by the base material, and this can be related to morphological defects of the weld bead. [ABSTRACT FROM AUTHOR]

In this work, an original algorithm, proposed in [1–2], has been used to predict the variable pressure-time load profile during a superplastic forming process, in order to get best performances, in terms of ductility, on the material. The so obtained curve has been used in experimental free bulging tests on an AZ31 magnesium alloy sheet. Tests results, in particular the maximum bulge height achieved by the material, have been compared with numerical results and with constant-pressure experimental tests. [ABSTRACT FROM AUTHOR]