Warm forming of aluminum alloy brazing sheet

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The proposed research will focus on the development, assessment and commercialization of manufacturing methods to fabricate next generation light weight thermal management systems by Dana Canada. The current research team recently completed a significant Collaborative R&D project entitled "Warm forming of aluminium alloy sheet" under funding from NSERC, the Ontario Research Fund {Initiative for Automotive Manufacturing Innovation) and Dana Canada. This previous project, referred to herein as Phase I, with the current APC proposal representing Phase II, has demonstrated that warm forming has strong potential to increase formability of brazing sheet, increasing the range of potential product designs and/or reducing the number of forming operations required to meet a particular design. As such, this research is ripe for commercialization and Dana Canada, with its partners at the University of Waterloo and CAN MET, wishes to pursue the next steps to realize commercial implementation of this warm forming technology within its manufacturing operations. Key requirements to be addressed in this project are further development of the warm forming process to: (i) extend the range of achievable deep draw performance and ascertain the potential of warm forming to produce consistently flat components for brazing; (ii) characterize the as-formed brazing performance and asbrazed corrosion performance of warm formed materials; and, (iii) develop production-ready warm forming processes and equipment. The primary research tasks include (a) Identification and characterization of high performance warm forming lubricants, (b) Warm forming experiments and process optimization for low cycle time, (c) warm forming model development and process optimization, and {d) characterization of as-formed component integrity, post forming braze assessment and as-brazed corrosion testing. This scope of work will feature experimental and analytical research that will serve as proof of concept of the warm forming processing route.