Papers by Author: Jürgen Hirsch

Abstract: The article investigates the effect of the strain rate on the driving force of recrystallization during hot working of the as-cast structure. For the study, we applied previously obtained experimental data of recrystallization kinetics during this stage of thermomechanical treatment. In addition, hot laboratory rolling, followed by saltpeter bath soaking, were performed in order to obtain supplemental data on grain structure size and orientations. Grain structure size was examined by optical microscopy, and its orientation was examined by X-ray texture analysis. The studies demonstrated, that overestimated recrystallization driving force not only results in erroneous kinetics estimation, but also gives excessive number of recrystallization centers and undersized grain structure. Besides, unaccounted effect of recrystallization driving force on grain size leads to distorted predictions of texture composition. In order to avoid this, it was recommended to apply an special exponential accumulated strain dependent coefficient.

Abstract: In electrical power systems bolted joints with bus bars made of aluminium are common, whereby the tendency towards higher operating temperatures can be observed. At higher temperatures a reduction of the joint force can occur due to creep and/or stress relaxation processes, which leads to an increasing electrical resistance and, in the worst case, to failed joints. The aim of this project is to increase the creep resistance (and to minimise the stress relaxation) of aluminium conductors for electrical applications without a significant reduction in their electrical conductivity – even after long-term exposure to elevated temperatures. The effect of dispersoids in different aluminium alloys on the longterm behaviour of currentcarrying joints at high temperatures (i.e. 140 °C) was investigated. Longterm tests on bolted joints with force measuring devices were performed to monitor the joint forces and to measure the joint resistances, both with and without current supply.

Abstract: In the present paper, an extended age hardening model for Al-Mg-Si alloys is presented. In this new approach the combined precipitation, yield strength and work hardening model, known as NaMo Version 1, has been further developed to account for the effects of room temperature storage and cold deformation on the resulting age hardening behaviour. Incorporation of these two new stages in NaMo largely increases the versatility of the model by allowing simulations of complex multi-stage industrial processing involving thermomechanical treatment as well. Part 1 of this work deals with the theoretical background and experimental validation of the extended version of NaMo, while Part 2 focuses on the new applications of the model by showing some numerical examples related to production of automotive body panels.

Abstract: The present investigation deals with modelling of the age-hardening behaviour of 6xxx series automotive sheet alloys. The basis for this work is the established precipitation model NaMo developed for coupled nucleation, growth, dissolution and coarsening in Al-Mg-Si extrusion alloys. It has recently been extended for applicability for Al-Mg-Si automotive sheet alloys by incorporating the important effects of room temperature (RT) storage and deformation prior to the final artificial ageing of Al-Mg-Si sheet alloys. The 6xxx automotive sheet alloys change due to natural ageing during the time elapsing between their processing and their paint baking in the customers process. This RT storage time has an impact on the artificial ageing response during the OEMs paint baking cycle. A second effect originates from the deformation introduced in the material during the part forming process prior to the artificial ageing in the paint bake cycle. This deformation leads to the introduction of dislocations which further modify the artificial ageing response by providing heterogeneous nucleation sites for nucleation of additional strengthening phases. Part 1 of this work deals with the theoretical background and experimental validation of the extended version of NaMo, while Part 2 focuses on the new applications of the extended model by simulation of ageing during paint baking according to typical customer requirements. The model validation is based on a comprehensive set of tensile tests. A comparison between model predictions and measurements shows reasonable agreement, and it is concluded that, after some further development, the model can be used to model the yield strength response of 6xxx automotive sheet alloys incorporating the (combined) effects of natural ageing, deformation and the accurate heat treatments in the paint bake cycle.

Abstract: Textures and related anisotropy effects which occur in certain industrial processes are presented for as-cast, deformed and annealed (recrystallized) Aluminium alloys and products. They are analyzed in detail and discussed based on their formation mechanisms, which are growth selection during solidification and the formation of new grains during casting and recrystallization, glide on selected slip planes during plastic deformation and oriented nucleation and oriented growth of new grains during recrystallization. Alloy composition and constitution that control microstructure evolution during processing (e.g. casting, extrusion, hot and cold rolling, annealing) determine the material quality and product performance.In these cases industrial processing of Aluminium alloys is specifically designed to control textures to achieve superior anisotropic properties and so better meet special product requirements. Examples are given for resulting properties, like strength and formability / anisotropy effects in packaging and automotive sheet applications. Other examples are given for the etching behaviour of high purity Aluminium capacitor foil and strength anisotropy of age hardened extrusions for aerospace applications.

Abstract: The effect of plastic deformation of Aluminium alloys at elevated temperatures is described and its effects on texture evolution in Aluminium and its alloys. The softening mechanisms involved are recovery, recrystallization and grain boundary sliding which reduce strain hardening and affect plastic deformation also in industrial fabrication and forming processes of Aluminium alloys, like (hot) forming, rolling, extrusion and superplastic forming. These effects that control high temperature formability and the resulting textures and final properties are described.

Abstract: The web-based e-learning tool “AluMATTER” is presented which can be accessed under the address “http://aluminium.matter.org.uk” and offers a new interactive course for students, engineers or technicians to learn all about Aluminium science and technologies. The e-learning program fulfils all distant learning requirements and intends to supplement regular teaching courses. It allows users to access the material in a context relevant to their own requirements and background.

Abstract: A new approach to improve existing and develop new simulation models and apply them in a sequence to simulate the complete production processes of Aluminium semi-finished products is described. The development has been a joint effort of academic and industrial partners developed in the frame of the VIR* European projects. It integrated advanced material models with industrial fabrication process models to predict the microstructures and properties in the complete production chain processes of Al sheet and profiles, i.e. by DC ingot casting, rolling and extrusion and analyze complex interactions of critical process parameters with the corresponding metallurgical mechanisms and predict the related material response and properties. The principles are discussed and examples are given for their successful application to simulate industrial fabrication processes.

Abstract: The texture evolution during hot and cold rolling of AlMg1Mn1 can body sheet is described and the related anisotropy effects during deep drawing are analysed quantitatively. The typical textures of rolled aluminium show the transition between ß-fibre orientations and cube recrystallization texture, depending on rolling temperature and strain. These correlate with transitions between 45° and 0°/90° ear heights in deep drawn cups which are described by a new method of Fourier series expansion. Processing parameters to achieve low anisotropy are discussed.