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

高强度铝板是一种很有前途的汽车结构件新材料，具有减轻汽车重量、提高燃油经济性和减少温室气体排放的潜力。然而，在室温冲压应用中，高强度铝板具有有限的延展性和成形性。因此，更几何复杂的汽车零件不能在室温下用高强度铝生产。诺贝丽斯作为汽车铝板的主要生产商，对使用高强度铝板冲压应用进一步减轻汽车重量感兴趣。提出了一项研究AA7xxx系列高强度铝板的温热（或高温）成形的研究计划。在这个项目中，我们将通过进行小型和大型实验以及各种汽车成形过程和材料塑性变形行为的计算机模拟，重点发展对上述板材成形行为的理解。该研究还将包括对高强度AA7xxx铝板热冲压/模具淬火新工艺的可行性研究。该工艺已在汽车冲压工业中用于高强度钢板。将考虑AA7075板材的两种变体：由主要合金元素制成的标准商业生产板材，以及由工业合作伙伴诺贝丽斯生产的下一代AAxxx板材。将通过开展基础研究和应用工艺开发研究来评估材料成分、加工、微观结构和基本机械性能对成形性的影响。该研究还将涉及与位于安大略省汉密尔顿的CanmetMaterials研究实验室的密切合作。

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.