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Elec ically-assis ed o ming o 5754 aluminium alloy unde
di e en s ain condi ions
DOBRAS Daniel1,a *, ZIMNIAK Zbigniew1,b, DZIUBEK Ma eusz1,c
1 Depa men o Mechanical Enginee ing, W ocław Uni e si y o Science and Technology, 5
Ignacego Łukasiewicza S ee , 50-371 W ocław, Poland
a[email p o ec ed], b[email p o ec ed], c[email p o ec ed]
Keywo ds: Elec oplas ic E ec , Dynamic Reco e y, Deep D awing
Abs ac . Elec ici y-assis ed o ming p ocesses can signi ican ly imp o e ma e ial duc ili y and
p ocess e iciency. Howe e , u he esea ch in o di e en s ain condi ions is necessa y, o
example, in s amping p ocesses. In his s udy, ensile and deep d awing es s o he 5754
aluminium alloy we e ca ied ou wi h he applica ion o cu en pulses on a specially cons uc ed
expe imen al se up. The s udy showed ha i is possible o inc ease he plas ici y o he ma e ial.
The main cause esponsible o he inc ease in plas ici y was dynamic eco e y.
In oduc ion
The use o ligh me al alloys wi h high speci ic s eng h helps educe he weigh o ehicles and
hus educe exhaus emissions in he au omo i e indus y [1]. The o mabili y o aluminium and
magnesium alloys is gene ally low a oom empe a u e [2]. Wa m and ho o ming p ocesses
imp o e o mabili y; howe e , his esul s in highe ene gy consump ion and gene a es p oblems
such as dimensional accu acy and lub ica ion e ec i eness educ ion [3].
The o mabili y o aluminium alloys (AA) can also be inc eased by applying cu en pulses
du ing i s de o ma ion. This me hod is called Elec ically-Assis ed Fo ming (EAF) and has many
ad an ages o e con en ional o ming me hods, such as educing low s ess and inc easing
ma e ial o mabili y [4]. P e ious s udies ha e shown ha hanks o he addi ional applica ion o
cu en pulses, i is possible o inc ease he elonga ion o he 5052-H32 aluminium alloy [5] and
he AZ91 magnesium alloy [6] e en mo e han h ee imes. This la ge inc ease in elonga ion can
be explained by he localized Joule hea heo y [7]. Ne e heless, o he s udies ha e shown ha
low- empe a u e pulsed cu en -assis ed de o ma ion can also lead o a signi ican imp o emen in
he plas ici y o zinc [8] and i anium alloys [9]. These changes can be explained by some a he mal
phenomena (elec oplas ic e ec ) [10] o econ igu a ion o c ys al la ice de ec s [9]. Fu he
esea ch is needed o p ecisely de e mine he impac o he mal and a he mal e ec s.
Al hough he physical basis o he phenomena occu ing du ing EAF p ocesses is s ill no
clea ly de ined, many a emp s ha e been made o implemen elec ically-assis ed (EA) indus ial
p ocesses. Zimniak e al. [11] showed ha i is possible o educe he d awing o ce in he coope
EA wi e d awing p ocess. The p oduc s ob ained in his way a e cha ac e ized by be e duc ili y,
wi h no dec ease in s eng h. Simila esul s we e ob ained in he olling p ocess o he AZ31
magnesium alloy [12] suppo ed by he applica ion o cu en pulses. Xie e al. [13] demons a ed
ha i is possible o inc ease he plas ici y o he AZ31B magnesium alloy shee in he EA deep
d awing p ocess. Howe e , in he case o o he alloys [14], [15] he inc ease in plas ici y was
insigni ican ; he e o e, mo e esea ch is needed o imp o e he e iciency o his p ocess.
Ma e ials and Me hods
Samples made o 5754 aluminium alloy in he o m o a 1 mm hick shee we e used in he es s.
The ma e ial was deli e ed in wo ha dening s a es: H111 and H22. In o de o ealize di e en
s ain condi ions, wo ypes o es s we e pe o med: ensile and deep d awing. An INSTRON 3369
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ensile machine was used o ca y ou he ensile es s wi h a s ain a e o 0.0025 s-1. Tensile
samples wi h a expe imen ally i ed gauge leng h o 75 mm and a gauge wid h o 12 mm, milled
along he olling di ec ion, we e used.
The E ichsen 142 Shee Me al Tes ing Machine was used o ca y ou deep d awing es s wi h
a punch speed o 0.4 mm/s. Two ope a ing modes we e used o implemen he deep d awing
p ocess: no mal (NL) and shee holde quick elease (SHQR). In he NL mode, a cons an blank
holde o ce was main ained h oughou he es . In SHQR mode, he blank holde o ce was
immedia ely educed om he ini ial alue o ze o a e eaching he se punch dep h alue.
A punch wi h a ci cula sec ion wi h a diame e o 30 mm and a adius o 6 mm and a die wi h
a diame e o 33.5 mm and a adius o 4 mm we e used o he deep d awing p ocess. Th ee samples
o di e en shapes and dimensions we e in ended o he deep d awing p ocess. Rec angula
sample No. 1 wi h dimensions o 66 by 12 mm was o med in he NL mode wi h a blank holde
o ce o 30 kN. Ci cula sample No. 2 wi h a diame e o 66 mm was o med in bo h modes wi h
a blank holde o ce o 40 kN. Sample No. 3, wi h expe imen ally i ed dimensions isible in
Fig. 1, was o med in he SHQR mode wi h a blank holde o ce o 40 kN. A lowe alue o he
blank holde o ce was used o sample No. 1 due o i s much smalle con ac a ea wi h he blank
holde han o o he samples.
Fig. 1. a) The shape and dimensions (in mm) o sample No. 3; b) Pa o he expe imen al se up
wi h sample No. 3.
The sel -cons uc ed cu en pulse gene a o ope a ing a a ol age o 2.52 V was used o apply
cu en pulses o he samples du ing he ensile and deep d awing p ocesses. Impo an pa ame e s
o he powe gene a o also include: maximum alue o he pulse cu en 15 kA and capaci y o a
bank o capaci o s 14 000 F. In he ensile es , cu en pulses we e deli e ed h ough elec odes
a ached o he sample. In he deep d awing es , cu en pulses we e deli e ed by dies ha we e
also elec odes, as shown in he scheme o he expe imen al se up (Fig. 2). Dies-elec odes we e
made o CuNi2Be coppe alloy wi h high conduc i i y and s eng h. In o de o a oid he low o
cu en o he machine, insula o s a e used, isible, among o he s, in Fig. 2. Fo his pu pose, he
sc ews used o build he expe imen al se up we e also made o non-conduc i e ma e ial. The
cu en was applied in he o m o pulsed cu en gene a ed by a unc ion gene a o . The pulsed
cu en was chosen because i allows o a g ea e inc ease in plas ici y han con inuous cu en
[9]. The cu en pa ame e s used we e ma ked in he o m p/d, whe e p is he pe iod and d is he
pulse du a ion. The ime p was he ime a e which he i s pulse was applied in he ensile es s.
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In he deep d awing es s, he applica ion o pulses began when he SHQR mode was ac i a ed o
a e eaching 3 mm o punch dep h (NL mode). The cu en lowing h ough he samples was
measu ed using a Rogowski coil and an oscilloscope. The FLIR 440 he mal imaging came a was
used o measu e he su ace empe a u e o samples p e iously pain ed wi h non-conduc i e black
sp ay. Each ensile and deep d awing es was epea ed h ee imes.
Obse a ions o he mic os uc u e o selec ed samples we e made using a Hi achi H-800
ansmission elec on mic oscope (TEM) ope a ing a a ol age o 150 kV. Specimens o
mic os uc u e obse a ion we e hinned by g inding and hen elec ochemically polished. Finally,
he 3 mm hin discs we e ion milled o ob ain su icien quali y o specimens.
Fig. 2. Scheme o he elec ically-assis ed deep d awing expe imen al se up.
Resul s and Discussion
The enginee ing s ass-s ain cu es o he aluminium alloys 5754-H22 and 5754-H111 wi h and
wi hou pulsed cu en applica ion a e shown in Figu e 3a and 3b, espec i ely. I is clea ly seen
ha he applica ion o cu en pulses esul s in an inc ease in he o al elonga ion o he 5754
aluminium alloy in bo h he H22 (by 105%) and H111 (by 48%) s a es. This is less han ha o
5052-H32 aluminum alloy [5], bu mo e han ha o 5083 aluminum alloy in a ious ha dening
s a es [16]. When a cu en pulse is applied, he sample empe a u e inc eases signi ican ly. A he
same ime, he s ess alue on he s ess-s ain cu e d ops d ama ically. In his s udy, he nominal
cu en densi y ( he cu en alue, measu ed by he Rogowski coil, di ided by he c oss sec ion
a ea o he sample) was 200 A/mm2. This d op in s ess is mainly caused by he mal expansion
and so ening due o Joule hea ing. Howe e , jus be o e he nex pulse is applied, he empe a u e
d ops almos o he oom alue [17]. The lack o s ess inc ease o he alue co esponding o he
cu e wi hou he applica ion o cu en pulse, as well as he inc ease in ma e ial plas ici y, is
explained by he annealing o he ma e ial. The maximal alues o he sample su ace empe a u e
eco ded by he he mal came a a e 332 and 295 °C o alloys in he H22 and H111 s a es,
espec i ely. Ne e heless, acco ding o he localized Joule hea heo y, he empe a u e nea g ain
bounda ies and disloca ion clus e s could ha e been empo a ily highe [7]. The e o e, hese we e
places pa icula ly sui able o eco e y and ec ys alliza ion p ocesses. I should be no ed ha he
a e age su ace empe a u e o he sample du ing he es was less han 150 °C. The sample unde
he H22 condi ion achie ed a g ea e inc ease in elonga ion, and was in ended o u he es s.
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Fig. 3. Enginee ing s ess-s ain cu es o 5754 AA in he a) H22 and b) H111 s a e wi h and
wi hou pulsed cu en applica ion.
Fig. 4a-b p esen s he o ce-displacemen deep d awing cu es ( o ce a punch and punch
displacemen ) o he 5754-H22 aluminium alloy wi h and wi hou pulsed cu en applica ion. The
o ce-displacemen cu es o samples No. 1 and 2 ( o bo h ope a ing modes) a e p esen ed in
Fig. 4a. The e a e no isible changes in he cou se o he cu e and ma e ial plas ici y as a esul
o he applica ion o cu en pulses in hese p ocesses. The de ailed e ec o cu en pulses on he
punch dep h o samples No. 1 and 2 is shown in Fig. 5a. No e ha he s ess d ops in he cu es
o selec ed samples No. 2 and 3 esul s om hei o ming in he SHQR mode. A sligh bu isible
6% inc ease in punch dep h was obse ed o sample no. 3 (Fig. 5b). The a e age alues o he
maximal empe a u es eco ded du ing deep d awing es s wi h he applica ion o cu en pulses
a e shown in Fig. 6a-b.
Fig. 4. Deep d awing o ce-displacemen cu es o 5754-H22 AA o a) samples No. 1 and 2 and
b) sample No. 3 wi h and wi hou pulsed cu en applica ion.
The sample empe a u es achie ed in deep d awing p ocesses a e much lowe han hose o
ensile es s, which is he main eason o he sligh o no inc ease in he plas ici y o he ma e ial.
In he case o sample No. 2, i s c oss-sec ion was oo la ge o ob ain a use ul cu en densi y alue.
The empe a u e o sample No. 2 was no g ea e han 50 °C, and o sample No. 3 i was abou
100 °C, which allowed o a sligh inc ease in he punch displacemen . Al hough he empe a u e
o sample No. 1 was he highes (abou 150 °C), i did no change he plas ici y o he ma e ial.
This can be explained by he ac ha he sample had a small olume and e en hough i
empo a ily eached he highes empe a u e alues, i was hen immedia ely cooled. Fu he
esea ch will be conduc ed, including modi ica ions o he expe imen al se up, in o de o inc ease
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he plas ici y o aluminium alloys in his p ocess. Making dies om a high-s eng h coppe alloy
has he ad an age ha cu en pulses can be deli e ed only o a selec ed pa o he o med shee .
Thanks o his, i is possible o educe he amoun o ene gy used in he p ocess. Un o una ely,
empe a u e plays a key ole in elec ically-assis ed p ocesses. The small olume o he hea ed
ma e ial esul s in quick hea abso p ion and hus lowe plas ici y o he ma e ial.
Fig. 5. In luence o cu en pa ame e s on he heigh o he d awpieces o 5754-H22 AA o
a) samples No. 1 and 2 and b) sample No. 3.
Fig. 6. In luence o cu en pa ame e s on he maximal empe a u e o he d awpieces o
5754-H22 AA o a) samples No. 1 and 2 and b) sample No. 3.
The applica ion o cu en pulses esul ed in a signi ican inc ease in he plas ici y o he 5754-
H22 aluminium alloy in he ensile es . The e o e, TEM s udies we e pe o med o e alua e he
e ec o cu en pulses on mic os uc u e changes. Fo his pu pose, wo addi ional EA ensile
es s we e pe o med and s opped a e he applica ion o he second and ou h pulses. When he
ensile es is s opped exac ly a e he pulse is applied, i is possible o p ecisely de e mine i s
e ec on he mic os uc u e. In addi ion, a one non-EA ensile es was pe o med and s opped a
he same s ain alue as he EA ensile es s opped a e he second pulse. Specimens we e cu
om he cen e o he samples hus ob ained o mic os uc u e analysis.
Fig. 7a shows he mic os uc u e o he non-EA sample. F equen ly occu ing local a eas wi h high
disloca ion densi y and he cellula disloca ion s uc u e o subg ains a e cha ac e is ic images o
samples a e cold de o ma ion. Subg ains o ma ion is a ypical ea u e o ma e ials wi h such
high s acking aul ene gy as aluminium alloys. On he o he hand, subg ains we e also eco ded
in EA samples (Fig. 7a-b, sample a e he applica ion o he ou h pulse); howe e , hey we e
su ounded by low-angle g ain bounda ies (LAGBs) and no a eas wi h high disloca ion densi y
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[18]. The p esence o such subg ains wi h an in e nal s uc u e wi h a low numbe o disloca ions
o wi hou hem is a ypical con igu a ion o he ma e ial a e he eco e y p ocess. Single, small
g ains, iden i ied as newly ec ys allized, we e also isible on he su ace o he analyzed specimen
(Fig. 7c). The empe a u e o he ma e ial ha occu ed (332 °C) and he app op ia e amoun o
accumula ed de o ma ion ene gy we e su icien o s a he dynamic ec ys alliza ion p ocess
(DRX) locally [19]. The applica ion o a cu en pulse caused he empe a u e o inc ease o a alue
esul ing in he ini ia ion o he dynamic ec ys alliza ion p ocess. Howe e , his p ocess ook oo
sho allow ec ys alliza ion o co e a la ge olume o ma e ial. I is wo h no ing ha he
mic os uc u e ea u es indica ed in Fig. 7b-d we e p esen in bo h samples a e he applica ion o
he second and ou h pulses.
Fig. 7. B igh - ield TEM images o specimens ob ained om a) non-pulsed, b-d) pulsed ensile
es s o 5754-H22 AA.
Summa y
The in luence o cu en pulses on he o mabili y o he 5754 aluminium alloy was p esen ed in
ensile and deep d awing es s. The esea ch used a new expe imen al se up (wi h specially
designed dies) o ca y ou he deep d awing p ocess wi h he applica ion o cu en pulses. The
s udy showed ha i is possible o signi ican ly inc ease he elonga ion o aluminium alloys in EA
ensile es s. I is possible o inc ease he elonga ion by mo e han 100%. The main mechanism
esponsible o he inc ease in elonga ion was he dynamic eco e y p ocess. TEM s udies showed
he p esence o subg ains su ounded by LAGBs, as well as single DRX g ains. Howe e , due o
he oo low empe a u e alue, he o mabili y o he 5754-H22 aluminium alloy in he deep
d awing es inc eased sligh ly. These s udies showed ha 5754 aluminum alloy can be used in
elec ically-assis ed o ming echnology, in pa icula in he H22 condi ion. Un o una ely, due o
excessi e hea abso p ion by he ools, hei modi ica ions a e necessa y o inc ease he plas ici y
o he ma e ial in he deep d awing p ocess.
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Acknowledgmen s
This wo k was suppo ed by he Na ional Science Cen e (g an No. 2022/45/N/ST8/03048).
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