Heat-assisted single point incremental forming of Mg-Zn-Zr alloy

Heat-assisted single point incremental forming of Mg-Zn-Zr alloy

OZDEN Ecem, VANHOVE Hans, BRAEM Annabel, DUFLOU Joost R.

download PDF

Abstract. Magnesium-zinc-zirconium (Mg-Zn-Zr) alloys, with their biocompatibility and biodegradability, exhibit great potential for biomedical applications. However, forming complex geometries poses a challenge due to the low formability of magnesium. Single Point Incremental Forming (SPIF) has emerged as a promising rapid manufacturing technique capable of producing complex-shaped, high-quality products. This preliminary study aims to investigate the feasibility of heat-assisted SPIF for Mg-Zn-Zr alloys, addressing formability at elevated temperatures, and the outcomes in terms of geometrical accuracy and material properties. Systematic parameter variations revealed that elevated temperatures and multistage toolpath strategies significantly improved formability, surpassing a 60° maximum wall angle. Nevertheless, this enhancement led to increased surface defects and reduced strength during forming at elevated temperatures. The key finding highlights the need for a balanced combination of elevated temperature and maximum wall angle to optimize surface quality and strength in complex geometries.

Single Point Incremental Forming, Heat-Assisted Forming, Magnesium Alloy

Published online 4/24/2024, 9 pages
Copyright © 2024 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA

Citation: OZDEN Ecem, VANHOVE Hans, BRAEM Annabel, DUFLOU Joost R., Heat-assisted single point incremental forming of Mg-Zn-Zr alloy, Materials Research Proceedings, Vol. 41, pp 1579-1587, 2024

DOI: https://doi.org/10.21741/9781644903131-175

The article was published as article 175 of the book Material Forming

Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.

[1] Chen, M., Ma, C., Liu, Q., Cheng, M., Wang, H., & Hu, X. (2023). Plastic Deformation Mechanism of High Strength and Toughness ZK61 Magnesium Alloy Plate by Multipass Horizontal Continuous Rolling. Materials, 16(3). https://doi.org/10.3390/ma16031320
[2] Duflou, J. R., Habraken, A. M., Cao, J., Malhotra, R., Bambach, M., Adams, D., Vanhove, H., Mohammadi, A., & Jeswiet, J. (2018). Single point incremental forming: state-of-the-art and prospects. In International Journal of Material Forming (Vol. 11, Issue 6). https://doi.org/10.1007/s12289-017-1387-y
[3] Leonhardt, A., Kurz, G., Victoria-Hernández, J., Kräusel, V., Landgrebe, D., & Letzig, D. (2018). Experimental study on incremental sheet forming of magnesium alloy AZ31 with hot air heating. Procedia Manufacturing, 15. https://doi.org/10.1016/j.promfg.2018.07.369
[4] Ambrogio, G., Filice, L., & Manco, G. L. (2008). Warm incremental forming of magnesium alloy AZ31. CIRP Annals – Manufacturing Technology, 57(1). https://doi.org/10.1016/j.cirp.2008.03.066
[5] Duflou, J. R., Verbert, J., Belkassem, B., Gu, J., Sol, H., Henrard, C., & Habraken, A. M. (2008). Process window enhancement for single point incremental forming through multi-step toolpaths. CIRP Annals – Manufacturing Technology, 57(1). https://doi.org/10.1016/j.cirp.2008.03.030
[6] Jackson, K., & Allwood, J. (2009). The mechanics of incremental sheet forming. Journal of Materials Processing Technology, 209(3). https://doi.org/10.1016/j.jmatprotec.2008.03.025
[7] Hirt, G., Bambach, M., Bleck, W., Prahl, U., & Stollenwerk, J. (2015). The Development of Incremental Sheet Forming from Flexible Forming to Fully Integrated Production of Sheet Metal Parts. https://doi.org/10.1007/978-3-319-12304-2_9
[8] Shi, F., Piao, N., Wang, H., Wang, J., Zang, Q., Guo, Y., Chen, C., & Zhang, L. (2023). Investigation of microstructure and mechanical properties of ZK60 magnesium alloy achieved by extrusion-shearing process. Journal of Materials Research and Technology, 25. https://doi.org/10.1016/j.jmrt.2023.05.256
[9] Mansoor, B., Mukhcrjee, S., & Ghosh, A. (2010). High strength ZK60 Mg plate produced by grain refinement and precipitation during alternate biaxial reverse corrugation (ABRC) process and friction stir process (FSP). Magnesium Technology.
[10] Xue, Y., Pang, X., Karparvarfard, S. M. H., Jahed, H., Luo, S., & Shen, Y. (2022). Corrosion Protection of ZK60 Wrought Magnesium Alloys by Micro‐Arc Oxidation. Metals, 12(3). https://doi.org/10.3390/met12030449