Low Temperature Warm Forming of Magnesium ZEK 100 Sheets for Automotive Applications

Abstract:

Cosma R&D investigated a low temperature warm forming process by which a magnesium ZEK 100 door inner part with a single-stage draw depth of 144 mm was successfully formed. The warm forming process is comprised of three steps: 1) heating pre-lubricated blanks in an oven at temperatures ranging from 215°C to 260 °C, 2) robotic transfer of the heated blank to a mechanical stamping press, 3) forming of the panel in room temperature stamping die at speed of about 160 mm/s. The effect of process parameters on the formability of the part, as well as, the post-forming properties including the mechanical properties, microstructure evolution and deformation thinning are also presented. The result indicates that Magnesium ZEK 100 exhibits superior low temperature warm formability over Magnesium AZ31B, and the developed warm forming process is promising and potential for volume production of magnesium automotive parts.

• Periodical: Materials Science Forum (Volumes 783-786)
• Pages: 431-436
• DOI: https://doi.org/10.4028/www.scientific.net/MSF.783-786.431
• Online since: May 2014
• Authors: Xiao Ping Niu*, Tim Skszek, Mark Fabischek, Alex Zak
• Keywords: Formability, Magnesium Sheet, Mechanical Property, Rear Earth, Warm Forming

References

[1] Fr. -W. Bach, B. -A. Behrens, M. Rodman, A. Rossberg, and G. Kurz, Macroscopic Damage by the Formation of Shear Bands during the Rolling and Deep Drawing of Magnesium Sheets, JOM, May 2005, 57-61.

DOI: 10.1007/s11837-005-0098-x

[2] Peter Friedman, USAMP-AMD602: Development of High-Volume Warm Forming of Low-Cost Magnesium SheetProject ID LM10, -(2010).

[3] Jon T. Carter, Raja K. Mishra, Two step forming with intermediate annealing of ZEK 100 alloy, Mg2012: 9th International Conference on Magnesium Alloys and their Applications, 695-702.

[4] Mariusz Boba, Michael J. Worswick, Raja Mishra, Jon Carter, Formability of AZ31B and ZEK100 Magnesium Alloy Sheets at Elevated temperatures, Mg2012: 9th International Conference on Magnesium Alloys and their Applications, 397-402.

[5] Nia R. Harrison, Andrey Ilinich, Peter A. Friedman, Jugraj Singh, Ravi Verma, Optimization of High-Volume Warm Forming for Lightweight Sheet, SAE, 2013-01-1170, April 8, (2013).

DOI: 10.4271/2013-01-1170