Currently, the automotive and aircraft industries are considering increasing the use of magnesium within their products due to its favorable strength-to-weight characteristics. However, the implementation of this material is problematic as a result of its limited formability. Partially addressing this issue, previous research has shown that Electrically-Assisted Manufacturing (EAM) improves the tensile formability of magnesium sheet metal. While these results are highly beneficial towards fabricating the skin of the vehicle, a technique for improving the production of the structural/mechanical components is also desirable. Given the influence that EAM has already exhibited on tensile deformation, the research herein focuses on incorporating this technique within forging operations. The potential benefit of using EAM on compressive processes has been demonstrated in related research where other materials, such as titanium and aluminum, have shown improved compressive behavior. Therefore, this research endeavors to amalgamate these findings to Mg AZ31B-O, which is traditionally hard to forge. As such, to demonstrate the effects of EAM on this alloy, two series of tests were performed. First, the sensitivity of the alloy to the EAM process was determined by varying the current density and platen speed during an upsetting process (flat dies). Then, the ability to utilize impression (shaped) dies was examined. Through this study, it was shown that the EAM process increases the forgeability of this magnesium alloy through improvements such as decreased machine force and increased achievable deformation. Additionally, the ability to form the desired final specimen geometry was achieved.

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