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Investigating the Formability of Aluminium Alloy Tubes by Rubber Bulge Testing

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Abstract:

Efficient characterization of formability of tubal sections is essential for designing lightweight aluminum extrusion components, particularly since the presence of weld seams and extrusion-induced inhomogeneities influence deformation behavior. This study evaluates the formability of Al–Mg–Si alloy tubes after being subjected to four different heat-treatment conditions, using a non-conventional rubber-assisted bulge test. A solid polyurethane (PU) plug was employed as pressure medium to enable full-scale deformation. Digital image correlation (DIC) was used to quantify circumferential and longitudinal strain evolutions, while post-fracture thickness measurements provided complementary insight into through-thickness strain.The measured circumferential strain at fracture ranged from 0.15 to 0.24 across the investigated tempers. The W-tempered condition exhibited the highest surface strain while maintaining moderate thickness reduction, whereas the soft-annealed tubes showed the largest thinning. The as-received and naturally aged conditions displayed similar deformation responses. These results demonstrate that tube formability, as evaluated by the present testing approach, is characterized by the combined evolution of surface strain and thickness reduction, both of which are influenced by heat treatment. Overall, the study shows that PU-assisted rubber bulge testing provides a practical and robust experimental framework for the comparative assessment of formability in extruded aluminum tubes.

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Periodical:

Solid State Phenomena (Volume 388)

Pages:

73-79

DOI:

https://doi.org/10.4028/p-W8FBjz

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Cite this paper

Online since:

April 2026

Authors:

Chanmi Moon*, Eren Can Sariyarlioglu, Togeir Welo

Keywords:

Al-Mg-Si Alloy, Extrusion, Formability, Rubber Bulge Testing

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Creative Commons CC BY 4.0

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* - Corresponding Author

References

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