Unveiling Thermal and Athermal Effects in Strain Hardening Removal of A6061 Aluminum Alloy

Abstract

This study explored the application of a high-density pulsed electric current (HDPEC) to mitigate strain hardening in a cold-rolled A6061 aluminum alloy while examining the simultaneous application of HDPEC with furnace heating to reveal the contributions of thermal and athermal effects. The results showed that significant strain-hardening relief was achieved through the HDPEC treatment, particularly at 300 A/mm² for 260 ms, resulting in a 23% reduction in strength and an 86% increase in ductility. Microstructural analysis revealed a shift to fine and equiaxed grains with reduced dislocation density, which was primarily attributed to thermal effects. HDPEC annealing exhibits superior efficiency compared to the conventional annealing treatment, offering cost and time advantages. In addition, this study validated the synergistic impact of HDPEC and furnace heating, with furnace heating supplementing energy requirements, facilitating practical HDPEC implementation. These findings suggest that the HDPEC method and the combined method with conventional heating are promising alternatives for strain-hardening alleviation in A6061 aluminum alloy manufacturing, supporting the development of an eco-friendly and efficient process. Graphical Abstract