RESUMO
Magnesium alloys play an essential role in metallic lightweight construction for modern mobility applications due to their low density, excellent specific strength, and very good castability. For some years now, degradable implants have also been made from magnesium alloys, which, thanks to this special functionality, save patients a second surgery for explantation. New additive manufacturing processes, which are divided into powder-based and wire-based processes depending on the feedstock used, can be utilized for these applications. Therefore, magnesium alloys should also be used here, but this is hardly ever implemented, and few literature reports exist on this subject. This is attributable to the high affinity of magnesium to oxygen, which makes the use of powders difficult. Therefore, magnesium wires are likely to be used. In this paper, a magnesium-based nanocomposite wire is made from an AM60 (Mg-6Al-0.4Mn) (reinforced with 1 wt% AlN nanoparticles and containing calcium to reduce flammability), using a high-shear process and then extruded into wires. These wires are then used as feedstock to build up samples by wire-arc directed energy deposition, and their mechanical properties and microstructure are examined. Our results show that although the ductility is reduced by adding calcium and nanoparticles, the yield strength in the welding direction and perpendicular to it is increased to 131 MPa.
RESUMO
Metal matrix nanocomposites are attracting attention because of their great potential for improved mechanical properties and possible functionalization. These hybrid materials are often produced by casting processes, but they can also develop their property profile after hot working, e.g., by forging or extrusion. In this study, a commercial cast magnesium alloy AM60 was enriched with 1 wt.% AlN nanoparticles and extruded into round bars with varied extrusion rates. The same process was carried out with unreinforced AM60 in order to determine the influences of the AlN nanoparticles in direct comparison. The influence of extrusion speed on the recrystallization behavior as well the effect of nanoparticles on the microstructure evolution and the particle-related strengthening are discussed and assessed with respect to the resulting mechanical performance.
RESUMO
In most forming processes based on tailored blanks, the tool material remains the same as that of sheet metal blanks without tailored properties. A novel concept of lightweight construction for deep drawing tools is presented in this work to improve the forming behavior of tailored blanks. The investigations presented here deal with the forming of tailored blanks of dissimilar strengths using tailored dies made of two different materials. In the area of the steel blank with higher strength, typical tool steel is used. In the area of the low-strength steel, a hybrid tool made out of a polymer and a fiber-reinforced surface replaces the steel half. Cylindrical cups of DP600/HX300LAD are formed and analyzed regarding their formability. The use of two different halves of tool materials shows improved blank thickness distribution, weld-line movement and pressure distribution compared to the use of two steel halves. An improvement in strain distribution is also observed by the inclusion of springs in the polymer side of tools, which is implemented to control the material flow in the die. Furthermore, a reduction in tool weight of approximately 75% can be achieved by using this technique. An accurate finite element modeling strategy is developed to analyze the problem numerically and is verified experimentally for the cylindrical cup. This strategy is then applied to investigate the thickness distribution and weld-line movement for a complex geometry, and its transferability is validated. The inclusion of springs in the hybrid tool leads to better material flow, which results in reduction of weld-line movement by around 60%, leading to more uniform thickness distribution.