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Comparison of electromagnetic forming of friction stir-welded blanks of dissimilar material AA 5052-AA 6061 with conventional forming process

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Abstract

In this work, studies on formability of Tailor Welded Blanks (TWB) were carried out by means of both quasi-static and high speed forming process. TWBs were manufactured as welded blanks of dissimilar material combination. Welding of AA 5052-H32 to AA 6061-T6 aluminium alloy of 1 mm thickness was done with the help a friction stir welding (FSW) process. Limit dome height (LDH) test was performed by both conventional hydraulic press forming (HPF) and by a high-speed forming process called electromagnetic forming (EMF) process, to investigate the forming behaviour of the TWB. Subsequently forming limit curves (FLCs) were plotted to quantify forming behaviour. Dome heights and FLCs of TWB and base materials are compared. Similar comparison has been made between conventional forming and EM forming process. It is found that the formability of TWB increases considerably with EMF process with base AA 5052 material showed largest increase in formability. Effect of weld line offset on the formability was also investigated. When the weld line was offset by 25 mm towards AA 6061 side of the TWB, the welded blanks showed maximum forming behaviour by EMF process in terms of both dome height and FLC.

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Authors and Affiliations

  1. Mechanical Engineering, Indian Institute of Technology Guwahati, IIT Guwahati, Amingaon, Guwahati, Assam, 781039, India

    Jyoti Kumar Doley & Sachin D. Kore

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  1. Jyoti Kumar Doley
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  2. Sachin D. Kore
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Correspondence to Jyoti Kumar Doley.

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Doley, J.K., Kore, S.D. Comparison of electromagnetic forming of friction stir-welded blanks of dissimilar material AA 5052-AA 6061 with conventional forming process. Int J Adv Manuf Technol 93, 3789–3797 (2017). https://doi.org/10.1007/s00170-017-0793-0

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  • DOI: https://doi.org/10.1007/s00170-017-0793-0

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