Abstract
This study aimed to investigate the micro deep drawability of the Zn–22Al alloy at room temperature in which it shows superplastic properties. To this goal, first the two-step equal channel angular extrusion (ECAE) process was carried out to obtain an ultra-fine-grained structure (UFG). Upon achieving the grain size of 200 nm, the formability of the alloy at room temperature and at a high strain rate was investigated both experimentally and numerically. Micro deep drawing experiments were performed at different deep drawing ratios (1.66, 1.84, 2.0, and 2.25) and for different sheet thicknesses (0.2, 0.4, and 0.6 mm). The finite element model of the micro deep drawing was also established to assess and compare the thickness variation in deep drawn parts. Results showed that the superplastic Zn–22Al alloy has a great potential in microforming applications. It was also noted that the limiting drawing ratio can be obtained as high as 2.25 in the room temperature condition.
Issue Section:
Research Papers
References
1.
Youssef
, K. M.
, Scattergood
, R. O.
, Murty
, K. L.
, Horton
, J. A.
, and Koch
, C. C.
, 2005
, “Ultrahigh Strength and High Ductility of Bulk Nanocrystalline Copper
,” Appl. Phys. Lett.
, 87
(9
), pp. 2003
–2006
. 10.1063/1.20341222.
Voyiadjis
, G. Z.
, Karon
, M.
, Rusinek
, A.
, Adamiak
, M.
, Camalet
, T.
, Bernier
, R.
, and Massion
, R.
, 2018
, “Effect of Severe Plastic Deformation by 120 Deg ECAP or Shock Impact on 6061 Aluminum Alloy at High Strain Rates
,” ASME J. Eng. Mater. Technol.
, 140
(4
), p. 041001
. 10.1115/1.40396903.
Valiev
, R. Z.
, and Langdon
, T. G.
, 2006
, “Principles of Equal-Channel Angular Pressing as a Processing Tool for Grain Refinement
,” Prog. Mater. Sci.
, 51
(7
), pp. 881
–981
. 10.1016/j.pmatsci.2006.02.0034.
Estrin
, Y.
, Rhee
, K.
, Lapovok
, R.
, and Thomson
, P. F.
, 2007
, “Mechanical Behavior of Alloy AA6111 Processed by Severe Plastic Deformation: Modeling and Experiment
,” ASME J. Eng. Mater. Technol.
, 129
(3
), p. 380
. 10.1115/1.27443965.
Geiger
, M.
, Kleiner
, M.
, Eckstein
, R.
, Tiesler
, N.
, and Engel
, U.
, 2001
, “Microforming
,” CIRP Ann.
, 50
(2
), pp. 445
–462
. 10.1016/S0007-8506(07)62991-66.
Xu
, J.
, Guo
, B.
, Shan
, D.
, and Li
, B.
, 2012
, “Study of Size Effects on Deformation Behavior and Formability in Micro Metal Forming of Ti Foil
,” ASME 2012 International Manufacturing Science and Engineering Conference
, Notre Dame, IN
, June 4–8
, pp. 263
–268
.7.
Molotnikov
, A.
, Lapovok
, R.
, Gu
, C. F.
, Davies
, C. H. J.
, and Estrin
, Y.
, 2012
, “Size Effects in Micro Cup Drawing
,” Mater. Sci. Eng. A
, 550
, pp. 312
–319
. 10.1016/j.msea.2012.04.0798.
Saotome
, Y.
, Yasuda
, K.
, and Kaga
, H.
, 2001
, “Microdeep Drawability of Very Thin Sheet Steels
,” J. Mater. Process. Technol.
, 113
(1–3
), pp. 641
–647
. 10.1016/S0924-0136(01)00626-49.
Parsa
, M. H.
, Ettehad
, M.
, Matin
, P. H.
, and Nasheralahkami
, S.
, 2010
, “Experimental and Numerical Determination of Limiting Drawing Ratio of Polypropylene-Al3105 Sandwich Sheets
,” ASME J. Eng. Mater. Technol.
, 132
(3
), p. 031004
. 10.1115/1.400126410.
Leu
, D.
, and Wu
, J.
, 2004
, “A Simplified Approach to Estimate Limiting Drawing Ratio and Maximum Drawing Load in Cup
,” ASME J. Eng. Mater. Technol.
, 126
(1
), pp. 116
–122
. 10.1115/1.163357411.
Mahabunphachai
, S.
, and Koç
, M.
, 2008
, “Investigation of Size Effects on Material Behavior of Thin Sheet Metals Using Hydraulic Bulge Testing at Micro/Meso-Scales
,” Int. J. Mach. Tools Manuf.
, 48
(9
), pp. 1014
–1029
. 10.1016/j.ijmachtools.2008.01.00612.
Yang
, C.
, Yin
, X. H.
, and Cheng
, G. M.
, 2013
, “Microinjection Molding of Microsystem Components: New Aspects in Improving Performance
,” J. Micromech. Microeng.
, 23
(9
), p. 093001
. 10.1088/0960-1317/23/9/09300113.
Engel
, U.
, and Eckstein
, R.
, 2002
, “Microforming—From Basic Research to Its Realization
,” J. Mater. Process. Technol.
, 125–126
, pp. 35
–44
. 10.1016/S0924-0136(02)00415-614.
Moktadir
, Z.
, Gao
, N.
, Zhang
, J.
, Bah
, M. T.
, Starink
, M. J.
, Qiao
, X. G.
, and Kraft
, M.
, 2010
, “Microembossing of Ultrafine Grained Al: Microstructural Analysis and Finite Element Modelling
,” J. Micromech. Microeng.
, 20
(10
), p. 105002
. 10.1088/0960-1317/20/10/10500215.
Rosochowski
, A.
, Presz
, W.
, Olejnik
, L.
, and Richert
, M.
, 2007
, “Micro-Extrusion of Ultra-Fine Grained Aluminium
,” Int. J. Adv. Manuf. Technol.
, 33
(1–2
), pp. 137
–146
. 10.1007/s00170-007-0955-616.
Langdon
, T. G.
, 2009
, “Seventy-Five Years of Superplasticity: Historic Developments and New Opportunities
,” J. Mater. Sci.
, 44
(22
), pp. 5998
–6010
. 10.1007/s10853-009-3780-517.
Kawasaki
, M.
, and Langdon
, T. G.
, 2007
, “Principles of Superplasticity in Ultrafine-Grained Materials
,” J. Mater. Sci.
, 42
(5
), pp. 1782
–1796
. 10.1007/s10853-006-0954-218.
Kawasaki
, M.
, Ahn
, B.
, Kumar
, P.
, Jang
, J. I.
, and Langdon
, T. G.
, 2017
, “Nano- and Micro-Mechanical Properties of Ultrafine-Grained Materials Processed by Severe Plastic Deformation Techniques
,” Adv. Eng. Mater.
, 19
(1
), pp. 1
–17
. 10.1002/adem.20160057819.
Kaibyshev
, O. A.
, 1992
, Superplasticity of Alloys, Intermetallides and Ceramics
, 1st ed., Springer-Verlag
, Berlin
.20.
Kawasaki
, M.
, Balasubramanian
, N.
, and Langdon
, T. G.
, 2011
, “Flow Mechanisms in Ultrafine-Grained Metals with an Emphasis on Superplasticity
,” Mater. Sci. Eng. A
, 528
(21
), pp. 6624
–6629
. 10.1016/j.msea.2011.05.00521.
Giuliano
, G.
, 2011
, Superplastic Forming of Advanced Metallic Materials
, Woodhead Publishing Series in Metals and Surface Engineering
, Sawston, Cambridge, UK
.22.
Tanaka
, T.
, Watanabe
, H.
, and Higashi
, K.
, 2003
, “Microstructure in Zn-Al Alloys After Equal-Channel-Angular Extrusion
,” Mater. Trans.
, 44
(9
), pp. 1891
–1894
. 10.2320/matertrans.44.189123.
Horita
, Z.
, Furukawa
, M.
, Nemoto
, M.
, Barnes
, A.
, and Langdon
, T.
, 2000
, “Superplastic Forming at High Strain Rates After Severe Plastic Deformation
,” Acta Mater.
, 48
(14
), pp. 3633
–3640
. 10.1016/S1359-6454(00)00182-824.
Hawkins
, R.
, and Belk
, J. A.
, 1976
, “Deep Drawing of Superplastic Material
,” Met. Technol.
, 3
(1
), pp. 516
–521
. 10.1179/03071697680339175525.
Kaibyshev
, O. A.
, Kazachkov
, I. V.
, and Salikhov
, S. Y.
, 1984
, “The Influence of Texture on Superplasticity of the Zn-22% Al Alloy
,” Acta Metall.
, 26
(12
), pp. 1887
–1894
. 10.1016/0001-6160(78)90101-326.
Dutta
, A.
, Charit
, I.
, Johannes
, L. B.
, and Mishra
, R. S.
, 2005
, “Deep Cup Forming by Superplastic Punch Stretching of Friction Stir Processed 7075 Al Alloy
,” Mater. Sci. Eng. A
, 395
(1–2
), pp. 173
–179
. 10.1016/j.msea.2004.12.01627.
Tsao
, L. C.
, Wang
, S. S.
, Yang
, C. F.
, and Chuang
, T. H.
, 2001
, “The Ultra-High Rate Superplastic Forming of a Zn-22Al Thin Sheet Material
,” Z. Metallkd.
, 92
(11
), pp. 1227
–1230
.28.
Tsao
, L. C.
, Yeh
, M. S.
, Lo
, C. J.
, Wu
, F. C.
, and Chuang
, T. H.
, 2000
, “Evaluation of Low Temperature Superplastic Formability for Zn-22Al Thin Sheets
,” Z. Metallkd.
, 91
(7
), pp. 613
–617
.29.
Yeh
, M. S.
, Lin
, H. Y.
, Lin
, H. T.
, and Chang
, C. B.
, 2006
, “Superplastic Micro-Forming With a Fine Grained Zn-22Al Eutectoid Alloy Using Hot Embossing Technology
,” J. Mater. Process. Technol.
, 180
(1–3
), pp. 17
–22
. 10.1016/j.jmatprotec.2006.04.01330.
Hirata
, T.
, Tanaka
, T.
, Chung
, S. W.
, Takigawa
, Y.
, and Higashi
, K.
, 2007
, “Relationship Between Deformation Behavior and Microstructural Evolution of Friction Stir Processed Zn-22 Wt% Al Alloy
,” Scr. Mater.
, 56
(6
), pp. 477
–480
. 10.1016/j.scriptamat.2006.11.02231.
Cetin
, M. E.
, Demirtas
, M.
, Sofuoglu
, H.
, Cora
, Ö. N.
, and Purcek
, G.
, 2016
, “Effects of Grain Size on Room Temperature Deformation Behavior of Zn-22Al Alloy Under Uniaxial and Biaxial Loading Conditions
,” Mater. Sci. Eng. A
, 672
, pp. 78
–87
. 10.1016/j.msea.2016.06.07232.
Zhang
, N. X.
, Kawasaki
, M.
, Huang
, Y.
, and Langdon
, T. G.
, 2014
, “The Significance of Self-Annealing in Two-Phase Alloys Processed by High-Pressure Torsion
,” IOP Conf. Ser.: Mater. Sci. Eng.
, 63
(1
), pp. 1
–9
. 10.1088/1757-899X/63/1/01212633.
Samekto
, H.
, and Roll
, K.
, “Finite Element Analysis of Superplastic Forming Process Using Ls-Dyna
,” 4th European LS-DYNA Users Conference
, Ulm, Germany
, May 22–23
, pp. 1
–16
.34.
Guo
, Z. X.
, Higashi
, K.
, and Ridley
, N.
, 1990
, “An Experimental Investigation of the Superplastic Forming Behavior of a Commercial Al-Bronze
,” Metall. Trans. A
, 21
(11
), pp. 2957
–2966
. 10.1007/BF0264721635.
Johnson
, W.
, and Mellor
, P. B.
, 1962
, Plasticity for Mechanical Engineers
, D. Van Nostrand Company Ltd.
, London
.36.
Irthiea
, I.
, Green
, G.
, Hashim
, S.
, and Kriama
, A.
, 2014
, “Experimental and Numerical Investigation on Micro Deep Drawing Process of Stainless Steel 304 Foil Using Flexible Tools
,” Int. J. Mach. Tools Manuf.
, 76
, pp. 21
–33
. 10.1016/j.ijmachtools.2013.09.00637.
Demirtas
, M.
, Purcek
, G.
, Yanar
, H.
, Zhang
, Z. J.
, and Zhang
, Z. F.
, 2015
, “Improvement of High Strain Rate and Room Temperature Superplasticity in Zn–22Al Alloy by Two-Step Equal-Channel Angular Pressing
,” Mater. Sci. Eng. A
, 620
, pp. 233
–240
. 10.1016/j.msea.2014.09.114Copyright © 2019 by ASME
You do not currently have access to this content.
