For metals, deformation is commonly conducted at elevated temperatures, reducing the overall process energy and cost. However, elevating the temperature has many drawbacks, including high tool/die adhesions, environmental reactivity, etc. Therefore, this study examines using an electrical current to reduce the deformation energy and presents electricity’s effects on the tensile properties of various materials. The influences of strain rate and cold work are also investigated. The results demonstrate that, when current flows through a metallic specimen, the material’s yield strength, flow stress, and elastic modulus are decreased; strain weakening occurs; and the total energy of deformation is decreased. These changes in the engineering stress-strain behavior occurred in all of the materials tested and are much greater than can be accounted for by resistive heating. However, the effects diminish with increasing strain rate. The analysis shows that applying electricity during deformation provides a viable alternative to increasing the workpiece temperature for deformation-based manufacturing processes.

Recent research has demonstrated that the mechanical properties of metals are altered when an electrical current is passed through the material. These studies suggest that titanium alloys, due to their low formability and need for dramatic improvement, should be subjected to additional study. The research presented herein further investigates the use of electricity to aid in the bulk deformation of Ti–6Al–4V under tensile and compressive loads. Extensive testing is presented, which documents the changes that occur in the formability of titanium due to the presence of an electrical current at varying current densities. Using carefully designed experiments, this study also characterizes and isolates the effect of resistive heating from the overall effect due to the electrical flow. This study clearly indicates that electrical flow affects the material beyond that which can be explained through resistive heating. The results demonstrate that an applied electrical current within the material during mechanical loading can greatly decrease the force needed to deform the titanium while also dramatically enhancing the degree to which it can be worked without fracturing. Isothermal testing further demonstrates that the changes are significantly beyond that which can be accounted for due to increases in the titanium’s temperature. The results are also supported by data from tests using pulsed and discontinuously applied current. Furthermore, current densities are identified that cause an enhanced formability behavior to occur. Overall, this work fully demonstrates that an electrical current can be used to significantly improve the formability of Ti–6Al–4V and that these improvements far exceed that which can be explained by resistive heating.

When fabricating parts, deformation is commonly conducted in a “warm” or “hot” state in order to reduce the total energy required to form the metal. However, there are several negative effects associated with this method of energy reduction (e.g., high tool/die adhesions, environmental reactivity, etc.) Hence, another more efficient method of reducing the total deformation energy would be very beneficial. This paper examines an alternative means of reducing the energy by applying an electrical current and also determines how the material’s tensile properties are affected while the current is present. Also investigated are the influences of strain rate and cold work on the electrical effects. The stress-strain curves indicate that, when current flows through a metallic specimen, the energy required to cause deformation is greatly decreased; demonstrating that electricity provides a viable alternative to increasing the workpiece temperature. However, the effect of the electricity diminishes with increasing strain rates.

Recent research has demonstrated that the mechanical properties of metallic materials are altered when an electrical current is passed through the material. These studies suggest that titanium, due to its low formability and potential for dramatic improvement, should be subjected to additional study. The research presented herein further investigates the use of electricity to aid in the bulk deformation of 6Al-4V titanium under tensile and compressive loads. Extensive testing is presented that documents the changes that occur in the formability of titanium due to the presence of an electron wind at varying current densities. Using carefully designed experiments, this study also characterizes and isolates the effect of resistive heating from the change due to the electrical flow alone. The results demonstrate that the presence of an electrical current within the material during deformation can greatly decrease the force needed to deform titanium while also dramatically enhancing the degree to which it can be worked without fracturing. Isothermal testing further demonstrates that the changes are significantly beyond that which can be accounted for due to increases in the titanium’s temperature. The results are also supported by data from tests using pulsed and discontinuously applied current. Furthermore, current densities are identified that cause an apparent superplastic behavior to occur. Overall, this work fully demonstrates that an electrical current can be used to significantly improve the formability of 6Al-4V titanium and that these improvements far exceed that which can be explained by resistive heating.