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1 Journal of Achievements in Materials and Manufacturing Engineering

1 2009

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Determination of the optimum forming conditions for warm tube hydroforming of ZM21 magnesium alloy

Esnaola J. A., Torca I., Galdos L., Garcia C.

Journal of Achievements in Materials and Manufacturing Engineering

2009

Vol. 32, nr 2

188-195

Purpose: Magnesium alloys are especially appropriate to decrease vehicle weight and consequently reduce fuel consumption. However, forming limitations regarded to their low formability at room temperature are found when being manufactured by conventional forming processes. Consequently, development of new forming techniques, such as warm tube hydroforming (WTHF), is needed to overcome such limitation. This way, WTHF allows combining the benefit of increasing forming temperature to raise the formability of these alloys with the widely known advantages of conventional Tube Hydroforming processes. In the current work, deformation mechanisms in ZM21 alloy were studied in order to determine the optimum forming conditions for warm forming processes. These working conditions were tested to form a ZM21 prototype by WTHF. Design/methodology/approach: In a first stage, specimens of ZM21 alloy were uniaxially tested at different temperatures up to 250şC at quasi-static strain rates, and microstructure of tested specimens was analysed. In a second stage, according to acquired knowledge, ZM21 tubes were formed by WTHF process and final mechanical properties and microstructure were analysed. Findings: Optimum forming conditions for WTHF of ZM21 alloy were determined. Practical implications: Magnesium tubular parts are very appropriate for automotive and aerospace industry due to their high strength to weigh ratio. Thus, WTHF processes allow obtaining excellent quality parts with complex shapes, difficult or even impossible to obtain by other forming techniques. Furthermore, the determined optimum forming conditions can be useful for other warm forming processes such as warm deep drawing. Originality/value: Deformation mechanisms and optimum forming conditions for ZM21 alloy, which presents advantages for warm forming processes, were determined. Furthermore, these forming conditions were tested in an emerging innovative forming process, WTHF.