Warm forging of magnesium AZ80 alloy for the control arm in an automobile

Yoon, Jonghun; Lee, Sang-ik

doi:10.1177/0954407014567909

Cited by 21 publications

(13 citation statements)

References 19 publications

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“…While the strength of the extruded material was increased by approximately 50 MPa after the T5 heat treatment, the strength of the forged and heat treated AZ80 only increased by 21 MPa, whereas its elongation to failure increased from ∼6% to 8%. In Reference [85] a control arm was forged in a two-step process at material temperatures of 265 • C and 365 • C (die temperature 250 • C and ram speed of 250 mm s −1 ) from extruded stock material. While the part forged at 265 • C showed the best mechanical properties, the part could not be fully formed.…”

Section: Az80mentioning

confidence: 99%

Mg-Alloys for Forging Applications—A Review

et al. 2020

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Interest in magnesium alloys and their applications has risen in recent years. This trend is mainly evident in casting applications, but wrought alloys are also increasingly coming into focus. Among the most common forming processes, forging is a promising candidate for the industrial production of magnesium wrought products. This review is intended to give a general introduction into the forging of magnesium alloys and to help in the practical realization of forged products. The basics of magnesium forging practice are described and possible problems as well as material properties are discussed. Several alloy systems containing aluminum, zinc or rare earth elements as well as biodegradable alloys are evaluated. Overall, the focus of the review is on the process control and processing parameters, from stock material to finished parts. A discussion of the mechanical properties is included. These data have been comprehensively reviewed and are listed for a variety of magnesium forging alloys.

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Section: Az80mentioning

confidence: 99%

Mg-Alloys for Forging Applications—A Review

et al. 2020

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“…Yoon [9] investigated the warm forming process of Al-Mg-Si-Cu alloy and proposed a reasonable process path. Yoon [10] explored the warm forging of AZ80 alloy for automobile and derived the corresponding process path. Yoon [9] and Yoon [10] analyzed the warm forging process of the alloy, but the combined process was not considered to be a parameter.…”

Section: State Of the Artmentioning

confidence: 99%

“…Yoon [10] explored the warm forging of AZ80 alloy for automobile and derived the corresponding process path. Yoon [9] and Yoon [10] analyzed the warm forging process of the alloy, but the combined process was not considered to be a parameter. Through a study of the softening, wear, and life of molds during warm forming, Choi [11] forwarded a method to predict the plastic deformation and wear of molds.…”

Section: State Of the Artmentioning

confidence: 99%

Numerical Simulation of Multistep Warm Extrusion Forming for the Outer Race of Universal Joint

Shen¹,

Bellus²

2018

JESTR

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Hot forging and machining by forging press is the traditional processing method of automotive universal joint outer race. The method has several disadvantages, such as high energy consumption, over-burning and oxidation tendency of the workpiece, large machining allowance, low surface quality, and poor mechanical properties. To solve the problem of low forming quality caused by the traditional processing method of outer race, a multistep warm extrusion forming process was proposed. The optimization of forming process parameters and the quality of this method was discussed in this study. The warm extrusion process was selected through process comparison and analysis. The initial billet size model was designed by applying the principle of constant volume, and four types of solutions were designed with the multistep combination of forward extrusion, upsetting, and backward extrusion. On the basis of finite element analysis method and metal forming flow theory, the numerical simulation was conducted by using the computer aided engineering (CAE) software Deform. The influence of billet diameter, initial extrusion temperature, number of working procedures, and die structure on the material flow, damage, temperature, and stress state in the forming process of outer race was analyzed. The optimal forming solution was obtained after optimization. Results demonstrate that the diameter of the outer race billet with this size is too small and tends to cause folding defects. The optimized billet is φ60 mm × 100 mm. When the initial extrusion temperature is high, the forming load is small and the forming quality is poor. Under the premise that the forming quality is guaranteed, the temperature is reduced as much as possible, and the optimized initial extrusion temperature is 800 o C. The increase in working procedure can reduce the maximum forming force, yet with slight effect. High quality can be obtained by the technology of first forward extrusion to the rod and then backward extrusion to the head. This study provides reference values for the warm extrusion forming of cup/rod-shaped parts.

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“…Characterization of the as-forged properties of forged Mg components in recent years has become T more widespread in literature. Many studies have focused on characterization of the monotonic structural properties of forged AZ80 and ZK60 Mg, in open die forgings [3][4][5] as well as for closed die forged components such as wheels [6][7][8], aerospace components [5,[8][9][10][11][12], and finally, automotive structural components [13][14][15][16][17][18][19][20][21][22][23][24]. In general, the main focus of these studies was the feasibility of achieving adequate material flow to produce the desired forged shape, whilst characterizing the resulting microstructure and quasi-static material properties.…”

Section: Introductionmentioning

confidence: 99%

Effect of thermomechanical processing defects on fatigue and fracture behaviour of forged magnesium

Gryguc

Behravesh

Jahed

et al. 2020

Frattura Ed Integrità Strutturale

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The microstructural origins of premature fatigue failures were investigated on a variety of forged components manufactured from AZ80 and ZK60 magnesium, both at the test specimen level and the full-scale component level. Both stress and strain-controlled approaches were used to characterize the macroscopically defect-free forged material behaviour as well as with varying levels of defect intensities. The effect of thermomechanical processing defects due to forging of a industrially relevant full-scale component were characterized and quantified using a variety of techniques. The fracture initiation and early crack growth behaviour was deterministically traced back to a combination of various effects having both geometric and microstructural origins, including poor fusion during forging, entrainment of contaminants sub-surface, as well as other inhomogeneities in the thermomechanical processing history. At the test specimen level, the fracture behaviour under both stress and strain controlled uniaxial loading was characterized for forged AZ80 Mg and a structure-property relationship was developed. The fracture surface morphology was quantitatively assessed revealing key features which characterize the presence and severity of intrinsic forging defects. A significant degradation in fatigue performance was observed as a result of forging defects accelerating fracture initiation and early crack growth, up to 6 times reduction in life (relative to the defect free material) under constant amplitude fully reversed fatigue loading. At the full-scale component level, the fatigue and fracture behaviour under combined structural loading was also characterized for a number of ZK60 forged components with varying levels of intrinsic thermomechanical processing defects. A novel in-situ non-contact approach (utilizing Digital-Image Correlation) was used as a screening test to establish the presence of these intrinsic defects and reliably predict their effect on the final fracture behaviour in an accelerated manner compared to conventional methods.

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Warm forging of magnesium AZ80 alloy for the control arm in an automobile

Cited by 21 publications

References 19 publications

Mg-Alloys for Forging Applications—A Review

Mg-Alloys for Forging Applications—A Review

Numerical Simulation of Multistep Warm Extrusion Forming for the Outer Race of Universal Joint

Effect of thermomechanical processing defects on fatigue and fracture behaviour of forged magnesium

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