Accurate Flow Characterization of A6082 for Precision Simulation of a Hot Metal Forming Process

The flow behaviors of metallic materials are sensitive to state variables, including strain, strain rate, and temperature. In particular, the temperature effect on the flow behavior is of great importance. The flow information is usually obtained at the sample strain rates and temperatures from the hot cylinder compression test. However, this test is inevitably exposed to undesirable effects of friction and temperature on flow characterization. This study reveals their impact on the flow curve of an A6082 alloy. The unique features of its flow behavior and the inaccuracy of as-received, primitive flow information are emphasized. Using a systematic way of correcting the friction and temperature effects, the flow curves with high accuracy in terms of the compression load–stroke curve obtained from the test are calculated. It was revealed that the both the friction and temperature compensation of the primitive flow curves bring a minor change in the flow curves of the A6082 alloy, which is quite different from other commercial light metals. This phenomenon caused by the unique features of the flow behavior of the A6082 or other aluminum alloys will be critical to solving various process and quality matters confronted by the engineers in the hot metal forming industry.