Microstructure Evolution, Constitutive Modelling, and Superplastic Forming of Experimental 6XXX-Type Alloys Processed with Different Thermomechanical Treatments

This study focused on the microstructural analysis, superplasticity, modeling of superplastic deformation behavior, and superplastic forming tests of the Al-Mg-Si-Cu-based alloy modified with Fe, Ni, Sc, and Zr. The effect of the thermomechanical treatment with various proportions of hot/cold rolling degrees on the secondary particle distribution and deformation behavior was studied. The increase in hot rolling degree increased the homogeneity of the particle distribution in the aluminum-based solid solution that improved superplastic properties, providing an elongation of ~470–500% at increased strain rates of (0.5–1) × 10(−2) s(−1). A constitutive model based on Arrhenius and Beckofen equations was used to describe and predict the superplastic flow behavior of the alloy studied. Model complex-shaped parts were processed by superplastic forming at two strain rates. The proposed strain rate of 1 × 10(−2) s(−1) provided a low thickness variation and a high quality of the experimental parts. The residual cavitation after superplastic forming was also large at the low strain rate of 2 × 10(−3) s(−1) and significantly smaller at 1 × 10(−2) s(−1). Coarse Al(9)FeNi particles did not stimulate the cavitation process and were effective to provide the superplasticity of alloys studied at high strain rates, whereas cavities were predominately observed near coarse Mg(2)Si particles, which act as nucleation places for cavities during superplastic deformation and forming.