INTEGRATED APPROACH TO THE SUPERPLASTIC FORMING OF MAGNESIUM ALLOYS

The economical and environmental issues associated with fossil fuels have been urging the automotive industry to cut the fuel consumption and exhaust emission levels, mainly by reducing the weight of vehicles. However, customers increasing demands for safer, more powerful and luxurious vehicles have been adding more weight to the various categories of vehicles, even the smallest ones. Leading car manufacturers have shown that significant weight reduction, yet satisfying the growing demands of customers, would not be feasible without the extensive use of lightweight materials. Magnesium is the lightest constructional metal on earth, offering a great potential for weight-savings. However, magnesium and its alloys exhibit inferior ductility at low temperatures, limiting their practical sheet metal applications. Interestingly, some magnesium alloys exhibit superplastic behaviour at elevated temperatures; mirrored by the extraordinarily large ductility, surpassing that of conventional steels and aluminium alloys. Superplastic forming technique is the process used to form materials of such nature, having the ability to deliver highly-profiled, yet very uniform sheet-metal products, in one single stage. Despite the several attractions, the technique is not widely-used because of a number of issues and obstacles. This study aims at advancing the superplastic forming technique, and offering it as an efficient process for broader utilisation of magnesium alloys for sheet metal applications. The focus is primarily directed to the AZ31 magnesium alloy, since it is commercially available in sheet form, possesses good mechanical properties and high strength/weight ratio. A general multi-axial anisotropic microstructure-based constitutive model that describes the deformation behaviour during superplastic forming is first developed. To calibrate the model for the AZ31 magnesium alloy, systematic uniaxial and biaxial stretching tests are carried out over wide-ranging conditions, using 3 specially-designed fixtures. In a collaborative effort thereafter, the calibrated constitutive model is fed into a FE code in conjunction with a stability criterion, in order to accurately simulate, control and ultimately optimise the superplastic forming process. Special pneumatic bulge forming setup is used to validate some proposed optimisation schemes, by forming sheets into dies of various geometries. Finally, the materials post-superplastic-forming properties are investigated systematically, based on geometrical, mechanical and microstructural measures

On the Measurement of Nakazima Testing Based Out-of-Plane Forming Limit Curves using 2D Digital Image Correlation

The strain compensation method for measuring in-plane forming limit curves (FLCs) using 2D digital image correlation developed previously [A method of measuring in-plane forming limit curves using 2D Digital Image Correlation, SAE Int. J. Mater. Manf., 2023] was modified and extended to more versatile and popular out-of-plane FLCs. The current study introduces a straightforward strain compensation technique for measuring Nakazima testing based out-of-plane FLCs utilizing an affordable single-camera (2D) DIC system. In this study, forming tests are performed on two automotive-grade sheet metal alloys: DP980 steel and a 6xxx series aluminum alloy using the Nakazima test method. The experiments are conducted on a customized setup that allows for simultaneous optical strain measurements using both a stereo DIC and a 2D DIC system. The FLCs are obtained by applying a temporal FLC computation approach to the two measurement sets. The results show that 2D DIC FLC points match those obtained by stereo DIC for both the materials after applying the proposed strain correction method

Uniaxially-Driven Controlled Biaxial Testing Fixture

A uniaxially-driven controlled biaxial testing fixture includes a base, a first coupler mounted to the base, and a load input drive rack mounted for linear movement with respect to the base. A second coupler and a first specimen grip are both mounted to the load input drive rack. Second, third and fourth specimen grips are also mounted for linear movement with respect to the base. First, second and third drive mechanisms connect the load input drive rack to the second, third and fourth specimen grips. Together the four specimen grips are oriented to provide biaxial application of force to a test specimen

Effects of Microstructure on the Strain Rate Sensitivity of Advanced Steels

The dependence of the strain rate sensitivity of advanced ~1 GPa tensile strength steels on the phases present in their microstructures was studied by testing different steels at 0.005 and 500 s−1. The high strain rate tests were performed using a Kolsky bar setup, while the quasi-static tests were performed using a universal testing machine. The two main steels of interest were the Ferrite-Martensite DP980 and the Ferrite-Martensite-Austenite QP980; the latter being a transformation induced plasticity (TRIP) assisted steel. For comparison, ferritic CR5 mild steel and austenitic stainless steel 201 were also tested under the same conditions. Though the differences in the steel chemistries were not taken into account, the results obtained here suggest a strong relationship between the phase-content of the steel and its response to the changes in the loading rate. The relationships between the observed mechanical behavior and the phases present in the microstructure are discussed

Genome-wide landscape establishes novel association signals for metabolic traits in the Arab population

While the Arabian population has a high prevalence of metabolic disorders, it has not been included in global studies that identify genetic risk loci for metabolic traits. Determining the transferability of such largely Euro-centric established risk loci is essential to transfer the research tools/resources, and drug targets generated by global studies to a broad range of ethnic populations. Further, consideration of populations such as Arabs, that are characterized by consanguinity and a high level of inbreeding, can lead to identification of novel risk loci. We imputed published GWAS data from two Kuwaiti Arab cohorts (n = 1434 and 1298) to the 1000 Genomes Project haplotypes and performed meta-analysis for associations with 13 metabolic traits. We compared the observed association signals with those established for metabolic traits. Our study highlighted 70 variants from 9 different genes, some of which have established links to metabolic disorders. By relaxing the genome-wide significance threshold, we identified ‘novel’ risk variants from 11 genes for metabolic traits. Many novel risk variant association signals were observed at or borderline to genome-wide significance. Furthermore, 349 previously established variants from 187 genes were validated in our study. Pleiotropic effect of risk variants on multiple metabolic traits were observed. Fine-mapping illuminated rs7838666/CSMD1 rs1864163/CETP and rs112861901/[INTS10,LPL] as candidate causal variants influencing fasting plasma glucose and high-density lipoprotein levels. Computational functional analysis identified a variety of gene regulatory signals around several variants. This study enlarges the population ancestry diversity of available GWAS and elucidates new variants in an ethnic group burdened with metabolic disorders.Peer reviewe

Genome-wide association study identifies novel risk variants from RPS6KA1, CADPS, VARS, and DHX58 for fasting plasma glucose in Arab population

Consanguineous populations of the Arabian Peninsula, which has seen an uncontrolled rise in type 2 diabetes incidence, are underrepresented in global studies on diabetes genetics. We performed a genome-wide association study on the quantitative trait of fasting plasma glucose (FPG) in unrelated Arab individuals from Kuwait (discovery-cohort:n = 1,353; replication-cohort:n = 1,196). Genome-wide genotyping in discovery phase was performed for 632,375 markers from Illumina HumanOmniExpress Beadchip; and top-associating markers were replicated using candidate genotyping. Genetic models based on additive and recessive transmission modes were used in statistical tests for associations in discovery phase, replication phase, and meta-analysis that combines data from both the phases. A genome-wide significant association with high FPG was found at rs1002487 (RPS6KA1) (p-discovery = 1.64E-08, p-replication = 3.71E-04, p-combined = 5.72E-11; beta-discovery = 8.315; beta-replication = 3.442; beta-combined = 6.551). Further, three suggestive associations (p-values <8.2E-06) with high FPG were observed at rs487321 (CADPS), rs707927 (VARS and 2Kb upstream of VWA7), and rs12600570 (DHX58); the first two markers reached genome-wide significance in the combined analysis (p-combined = 1.83E-12 and 3.07E-09, respectively). Significant interactions of diabetes traits (serum triglycerides, FPG, and glycated hemoglobin) with homeostatic model assessment of insulin resistance were identified for genotypes heterozygous or homozygous for the risk allele. Literature reports support the involvement of these gene loci in type 2 diabetes etiology.Peer reviewe

Integrated Approach to the Superplastic Forming of Magnesium Alloys

The economical and environmental issues associated with fossil fuels have been urging the automotive industry to cut the fuel consumption and exhaust emission levels, mainly by reducing the weight of vehicles. However, customers ’ increasing demands for safer, more powerful and luxurious vehicles have been adding more weight to the various categories of vehicles, even the smallest ones. Leading car manufacturers have shown that significant weight reduction, yet satisfying the growing demands of customers, would not be feasible without the extensive use of lightweight materials. Magnesium is the lightest constructional metal on earth, offering a great potential for weight-savings. However, magnesium and its alloys exhibit inferior ductility at low temperatures, limiting their practical sheet metal applications. Interestingly, some magnesium alloys exhibit superplastic behaviour at elevated temperatures; mirrored by the extraordinarily large ductility, surpassing that of conventional steels and aluminium alloys. Superplastic forming technique is the process used to form materials of such nature, having the ability to deliver highlyprofiled

Numerical Implementation and Validation of a Viscoelastic-Plastic Material Model for Predicting Curing Induced Residual Stresses in Adhesive Bonded Joints

One of the main challenges in the joining of multi-material components is the assessment of the nature and magnitude of the residual stresses developing in the adhesive bond during the heat curing manufacturing process. Numerical modeling of these residual stresses can provide insights for making informed decisions related to (i) material substrate properties; (ii) adhesive properties i.e., low, medium, or high stiffness; (iii) bondline geometry i.e., bondline width and bead thickness; (iv) curing cycle characteristics; and (v) fixation design i.e., type, spacing, the number of joints. This work presents a cure history-dependent viscoelastic-plastic material description for the modeling of adhesive bonded joints. The main highlight of the work is the multi-physics modeling package consisting of a curing kinetics model, a cure-dependent viscoelastic model, and a temperature, strain-rate dependent plastic model formulation which can be coded in any finite element solver. The modeling approach can predict the residual stresses in the adhesive bond due to the accumulated viscoelastic as well as plastic strains occurring during the heat curing process. For the purpose of validation, the model is coded into a user-defined material subroutine (UMAT) in LS-DYNA. The modeling approach is verified at a small specimen level by simulating a uniaxial tension specimen at various temperatures and strain rates. The performance of the modeling approach is further evaluated at the component level using specially designed experiments involving heat curing of a sub-sized multi-material automotive roof model. The thermal displacements and distortions in the roof structure captured using 3D digital image correlation are compared to the finite element model predictions. Several design guidelines related to adhesive selection and mechanical fixations are proposed as a result of the study

Advanced Anti-Buckling Device Coupled with Real-Time Digital Image Correlation for Complex Cyclic Tension-Compression Testing of Lightweight Materials

In sheet metal forming and stamping operations, modeling the behavior of sheet metal alloys for springback prediction is known to be very challenging, not only because of the complex models needed to account for kinematic hardening (such as the Yoshida-Uemori Model) but more importantly because of the experimental limitations of our ability to perform the complex tests needed to calibrate such models. For instance, reliable monotonic uniaxial compression tests and then cyclic tension-followed-by-compression tests are essential for characterizing the response of the material under those loading conditions, providing quantitative evaluation of the Bauschinger Effect and tension/compression asymmetry in the material, and ultimately generate the right data to calibrate the constitutive model. This work tries to shed some light on this topic by introducing a new anti-buckling device that is particularly designed to enable accurate and repeatable compression and cyclic testing. The device exerts side loading on the sheet test sample to prevent it from buckling during testing under compression loading conditions. The device is designed to address the limitations of other approaches and devices presented in the literature, and features control and monitoring of side forces, self-centering, and the ability to achieve large plastic compressive strains. More importantly, digital image correlation (DIC) is integrated with the anti-buckling device and testing load frame to provide accurate strain measurements. In this study, DIC was used in a real-time mode (unlike the typical post-deformation mode) to facilitate accurate load reversal during cyclic testing. For validation, the presented setup was used for testing two selected materials with practical applications in the automotive body sector: 6016-T4 aluminum and DP980 steel sheets. The results demonstrate how the developed setup and the integration with real-time DIC provide a robust and reliable means for generating high-quality curves for the different tests needed for the calibration of springback models

Experimental Methods to Capture Curing Induced Effects in Adhesive Bonded Joints

The rapidly increasing use of structural adhesives, especially in the joining of automotive body structures has motivated various investigations of the effects of adhesive curing process on joints. The automotive-grade structural adhesives require heat curing, which, in the meantime, performs thermal loading on the substrates and causes undesirable effects in the joint. For example, the curing process results in complex residual stresses in the adhesive bond which are detrimental to the performance of the adhesive bond and thereby the automobile body structure, particularly the crashworthiness. To thoroughly evaluate such effects, this paper consists of two parts. The first part presents an innovative experimental method to characterize the thermal effects of the heat curing process on a multi-material single lap shear joint using digital image correlation. The second part of the study compares the performance of residual stress-induced joints against stress-free joints under tension loading at different strain rates. The proposed experimental method and the corresponding results from this study are expected to help comprehensively understand the adhesive joining process and its potential side effects on the automobile body structure