In-situ surface analysis for surface engineering in metal forming of lightweight alloys

随着铝和镁等轻质材料在各个行业中的应用，需要了解金属成形过程中发生的摩擦学相互作用。事实上，来自工业调查的数据表明，影响金属成形工艺的两个关键因素是金属板成形的摩擦学和模具设计。这是因为轻质金属的成形受到这些金属与成形模具/工具之间的粘附的阻碍，这可能导致最终产品的表面质量以及工具寿命的降低。目前的模具表面处理和润滑剂不能完全防止这种金属/模具反应。因此，更好地了解模具和金属之间发生的摩擦学相互作用至关重要。这项研究旨在通过利用多方面的摩擦学方法来减轻相互作用。该方法将包括一个实验装置，旨在监测，分析和系统性地分析模具和工件表面之间的润滑滑动接触过程中发生的机制。该装置将包括一个高焦深显微镜和一个显微拉曼光谱仪，用于直接观察和金属和模具相互作用的3D表征。它还将配备激光三角传感器，用于润滑剂膜的现场测量和表征，这将确定由于模具表面纹理和超声波叠加而影响润滑和COF的机制。因此，该实验装置将有助于建立一种新的原位技术，用于确定和监测润滑条件，即润滑剂厚度和故障。实验结果也将被应用到一个平面应变压缩设置配备了激光三角传感器和超声波换能器/发生器系统，模拟金属成形过程中的表面相互作用。结果将证实表面织构和超声波对变形特性和表面质量的影响，特别是在金属成形发生的不同应变和应变速率下。总之，本研究项目将建立一种原位技术，用于监测润滑膜厚度和测试表面纹理和用于摩擦控制的超声波效果，这将有助于在加拿大金属成型工业中生产无表面缺陷的产品。成形行业将节省数百万美元的投资，用于纠正金属成形过程中引起的轻质材料表面缺陷，从而提高其效率。

The drive towards the application of lightweight materials such as aluminum and magnesium in various industries has led to the need for understanding the tribological interactions that occur during metal forming processes. In fact data from an industrial survey state two of the critical factors influencing metal forming processing are tribology of sheet metal forming and the design of dies. This is because the forming of lightweight metals is hindered by adhesion between these metals and the forming die/tool, which can lead to the reduction of the surface quality of the final product as well as tool life. Current die surface treatments and lubricants are unable to completely prevent this metal/die reaction. Therefore, a better understanding of the tribological interactions that occur between the die and metal is essential. This research seeks to mitigate the interactions by utilizing a multi-aspect tribological approach. The approach will consist of an experimental set-up designed to monitor, analyse and systematically characterise the mechanisms occurring during lubricated sliding contact between the die and workpiece surfaces. The set-up which will incorporate a high depth-of-focus microscope and a micro-Raman spectrometer for direct observation and 3D characterization of metal and die interactions. It will also be equipped with laser triangle sensors for the in-situ measurement and characterisation of the lubricant film which will determine the mechanisms influencing lubrication and COF due to die surface texturing and superposition of ultrasonic waves. Therefore, this experimental set-up will help to establish a novel in-situ technique for the determination and monitoring of lubrication conditions i.e. lubricant thickness and breakdown. The experimental results will also be applied to a plane strain compression set-up equipped with laser triangle sensors and ultrasonic wave transducer/generator system which simulates surface interactions in metal forming processes. The results will confirm the effect of surface texture and ultrasonic waves on deformation characteristics and surface quality especially at varying strains and strain rates at which metal forming occurs. In summary, this research project will establish an in-situ technique for monitoring lubrication film thickness and testing surface textures and ultrasonic waves effects used for friction control that will contribute to the production of surface defect free products in the Canadian metal forming industry. The forming industry will save millions of dollars that are invested to rectify surface defects on lightweight materials induced during metal forming and, therefore, increase their efficiency.**