Elevated temperature forming of 7xxx series aluminum sheet for automotive applications

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High strength aluminum sheet is a promising new material for automotive structural parts that has the potential to reduce vehicle weight, increase fuel economy and reduce greenhouse gas emissions. High strength aluminum sheet, however, has limited ductility and formability in room temperature stamping applications. Consequently, more geometrically complex automotive parts cannot be produced in high strength aluminum at room temperature. Novelis, as a major producer of automotive aluminum sheet, is interested in further vehicle weight reduction using high strength aluminum sheet for stamping applications. A research program involving a study of warm (or elevated) temperature forming of high strength aluminum sheet from AA7xxx series is proposed. In this project we will focus on developing an understanding of the forming behaviour of the above mentioned sheet materials by conducting experimental small-scale and large-scale experiments and computer simulations of various automotive forming processes and material plastic deformation behaviour. The study will also include a feasibility study of a new process of hot stamping/die quenching for high strength AA7xxx aluminum sheets. This process is already in use in the automotive stamping industry for high strength steel sheets. Two variants of AA7075 sheet will be considered: standard commercially produced sheet from primary alloying elements as well as a next generation AAxxx sheet, produced by the industrial collaborator, Novelis. The effect of material composition, processing, microstructure and basic mechanical properties on formability will be assessed by carrying out fundamental research and applied process development studies. The research will also involve a close partnership with CanmetMaterials Research Laboratory located in Hamilton, Ontario.