Characterisation - Processing - Manufacturing of Lightweight Materials _ Fadi-Clemson University
Transcript of Characterisation - Processing - Manufacturing of Lightweight Materials _ Fadi-Clemson University
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8/13/2019 Characterisation - Processing - Manufacturing of Lightweight Materials _ Fadi-Clemson University
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Characterisation Processing Manufacturing
ofLightweightMaterials
FadiAbu
Farha
AssistantProfessorofAutomotiveEngineering
Suite344CGEC
Office:(864)2837231
Mobile:(859)4892926
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MotivationsWhy
Lightweight
Materials?
Steel
is
still
dominant!
Greatweightsavingspotentials
Alotofchallengeshybridmaterials
Lightweightingisakeystrategyforreducingfuelconsumptionlevelsin
thetransportationsector
BMW5series
ALHSSs
AHSSs
CSs
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LightweightingResearch@CUICAROverall
Vision
MaterialCharacterisation
MaterialProcessing
Manufacturing
Goal:
GreaterUtilisationof
LightweightMaterials
in
the
TransportationSector
Methodology:
MaterialBased
Sustainable
ManufacturingOriented
IntegratedApproach
Understand,model
andpredict
material
behaviour
Modifyandoptimise
properties&structurefor
enhancedperformance
Improveprocesses
and
develop
new
techniques
LightweightStructures
Lightweight
Materials
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LightweightingResearch@CUICAROverall
Vision
MaterialCharacterisation
MaterialProcessing
Manufacturing
Goal:
GreaterUtilisationof
LightweightMaterials
in
the
TransportationSector
Methodology:
MaterialBased
Sustainable
ManufacturingOriented
IntegratedApproach
Understand,model
andpredict
material
behaviour
Modifyandoptimise
properties&structurefor
enhancedperformance
Improveprocesses
and
develop
new
techniques
LightweightStructures
Lightweight
Materials
AHSSteels
UHSSteels
Aluminium
Magnesium
CarbonFibreTitanium
?
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ResearchHighlightsMaterialCharacterisation
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MaindriveFormingtechniquesthatgohandinglovewithLWmaterials
GeneralMotors
MgAZ31B
AA5083
Warm/Hot Sheet FormingMagnesium, Aluminium and Titanium
1. WarmForming
2. QuickPlastic
Forming
[QPF]
(General
Motors)
3. SuperplasticForming[SPF](Boeing)
Mostoftheseprocessedrequirecharacteringmaterial
behaviouratextremeconditions(comparedtosteels).
Nostandardsinsomecases!
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GeneralMotorsSuperplasticandQuickplasticforming:
o Materialtestingandcharacterisation
o Constitutivemodelling
o Microstructuralexamination
o Processoptimisation
o Propertiesafterforming
o Frictionand
tribology*
Currentparts
Warm/Hot Sheet FormingMagnesium, Aluminium and Titanium
GeneralMotorsGeneralMotors
Formildsteels!
Optimisation!
Boeing
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Drive:DesignandOptimisationofHot
FormingofLightweightMetallicSheets
o Developedtesting
methodologies
for
lightweightmetallicmaterials.
o FromFormingLimitCurves(FLCs)
o ToFormingLimitSurfaces(FLS)
FLCs CompositeFLCs FLS
Lightweight Sheet Formability?At Extreme Conditions
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Drive:significantdifferencesin
performanceamongMgsheets!
Magnesium Sheets Production Issues!
Sheets
are
supplied
by
various
producers
A M
N O
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Drive:significantdifferencesin
performanceamongMgsheets!
FLCs
Magnesium Sheets Production Issues!
Post
forming
mechanical
properties Failure
Microstructuralexamination
Microstructure/Macrobehaviourrelationships
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ARAMIS5MfittedtoanINSTRON5985
loadframe
Tensile Testingwith DIC
ARAMIS5M
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Shownherearetheresultsofatensile
testonMgAZ31Bspecimen
Tensile TestResults
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ARAMIS5Musedtomonitorsheet
deformationduring
Nakajima
test
Biaxial Testingwith DIC
ARAMIS5M
BallPunch
Blankholder
Mirror
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WithDIC
Preliminary tests
Thisspecimenwasbulgedto~500psi
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ResearchHighlightsMaterial
Processing
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Steelisdominant.Andwillstaydominantforthenextdecade(atleast)
Ultra High Strength Steels03rd Gen. AHSSs
Wehaveachievedalotwithsteels.
Wearepushingformore:
higherstrength>1000MPa
Highductility>25%
Movingfrom01st Gen.
To03rd Gen.
USS
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Steelisdominant.Andwillstaydominantforthenextdecade(atleast)
Ultra High Strength Steels03rd Gen. AHSSs
Wehaveachievedalotwithsteels.
Wearepushingformore:
higherstrength>1000MPa
Highductility>25%
Movingfrom01st Gen.
To03rd Gen.
USS
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Drive:Forprocessing/formingbulklightweightmaterials
Fromfrictionstirwelding/processingofsheetstofrictionstirformingofbulkmaterial
Processingtoolmovesaxially!
Bulk Friction Stir FormingConcept
Bulk friction stir
forming (BFSF)
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Forprocessing/formingbulklightweightmaterials
Itcouldbeaviableprocessing/formingtechnique,particularlyforhardtodeform
materials.
such
as
magnesium
alloys.
Stirringheatsthematerial(tosoftenit),thus
Facilitatesductiledeformation
Bulk Friction Stir FormingWhy?
Bulk friction stir
forming (BFSF)
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Previous/CurrentWork
Thisform:FrictionStirBackExtrusion
Energyefficient
tube
forming
process
(Al
&
Mg)
Grainrefinementandothergreatpotentials!
Noneedforpostprocessheattreatment.
Bulk Friction Stir FormingFriction Stir Back Extrusion (FSBE)
AA6063
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Previous/CurrentWork
Thisform:FrictionStirBackExtrusion
Energyefficient
tube
forming
process
(Al
&
Mg)
Grainrefinementandothergreatpotentials!
Noneedforpostprocessheattreatment.
Bulk Friction Stir FormingFriction Stir Back Extrusion (FSBE)
AA6063
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Significantgrainrefinement
ForMagnesium:
Bulk Friction Stir FormingFriction Stir Back Extrusion (FSBE)
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Challenges
ForMagnesium:
Bulk Friction Stir Forming
Friction Stir Back Extrusion (FSBE)
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Challenges
ForMagnesium:
Bulk Friction Stir Forming
Friction Stir Back Extrusion (FSBE)
AA6063
MgAZ31BF
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OneofseveralSPDtechniques;usedtoproduceultrafinegrainedmaterials.
Increasestrengthbygrainrefinement
Ithas
multiple
advantages
over
other
SPD
techniques
(fromapracticalpointofview):
Canproduceprocessedmaterialinbulksizes(sheets)
Usesatypicalrollingmill(nosubstantialadditionalcosts)
Outputsizeissimilartothestartingsize
Accumulative Roll Bonding
Grain Refinement for Strength Enhancement
ARBSchematic
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Previous/CurrentWork
ProcessingCPTitoincreaseitsstrengthtolevelscomparabletothoseoftheTi6Al4V
WarmARB
processing
can
produce
same
grain
refinement
levels
of
cold
ARB
processing
Accumulative Roll Bonding
Grain Refinement for Strength Enhancement
CPTiARBprocessed@~450C
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Previous/CurrentWork
ProcessingCPTitoincreaseitsstrengthtolevelscomparabletothoseoftheTi6Al4V
Evolutionof
grain
geometry;
strength/grain
size
relationship
Accumulative Roll Bonding
Grain Refinement for Strength Enhancement
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Previous/CurrentWork
ProcessingCPTitoincreaseitsstrengthtolevelscomparabletothoseoftheTi6Al4V
Postprocessing
heat
treatment
could
increase
both
strength
and
ductility
Accumulative Roll Bonding
Grain Refinement for Strength Enhancement
ARB@400CPPT@250Cfor10min. ARB@450CPPT@450Cfor10min.
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ResearchHighlightsAdvanced
Manufacturing
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Previous/CurrentWork
Thisform:FrictionStirBackExtrusion
Energyefficient
tube
forming
process
(Al
&
Mg)
Grainrefinementandothergreatpotentials!
Noneedforpostprocessheattreatment.
Bulk Friction Stir Forming
Friction Stir Back Extrusion (FSBE)
AA6063
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Previous/CurrentWork
Thisform:FrictionStirBackExtrusion
Energyefficient
tube
forming
process
(Al
&
Mg)
Grainrefinementandothergreatpotentials!
Noneedforpostprocessheattreatment.
Bulk Friction Stir Forming
Friction Stir Back Extrusion (FSBE)
AA6063
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FutureWork
o Evenrecyclingscrapmetaldirectlyintoafinalproduct
Bulk Friction Stir Forming
Expand to Forging and Recycling
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Accumulative Roll Bonding
Modify: ISR for Texture control
FutureWork
Isolatedshearrollingfortexturecontrol
Rollingwithout
bonding
Preliminaryresultsareencouraging!
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Accumulative Roll Bonding
Modify: ISR for Texture control
FutureWork
Isolatedshearrollingfortexturecontrol
Rollingwithout
bonding
Preliminaryresultsareencouraging!
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GeneralMotors
Complexpartscanbeformedinonestep,
comparedtoconsolidatingmultipleparts
FromWarm/HotPneumaticSheetMetalForming
o SPF/QPF
TowardsmoreSustainableManufacturingConcepts
o Reverse/forwardforming
Reverse/Forward Sheet Forming
Cyclic Sheet FormingGeneralMotors
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o Basedonhotstampingofboronsteels(yetwithnomartensitictransformation!)
o EconomicyetfastproductionofMgandAlsheetcomponents
Hot Blank Cold Die Forming
For Magnesium and Aluminium Sheets
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Hot Blank Cold Die Forming
For Magnesium and Aluminium Sheets
PreliminarySetupandTesting
o Coolingcurves
o
Forming
window
for
aluminium
and
magnesium
is
big
enoughforHBCD
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WhatsNext
BMW5series
AHybridofdifferentmaterials
VolvoXC60
AudiA8(2010)
FutureisAdvanceandIntegrate
BMWi3
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WhatsNext
BMW5series
AHybridofdifferentmaterials
VolvoXC60
AudiA8(2010)
FutureisAdvanceandIntegrate
BMWi3
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Thank You !!!