Development of the Fast Light Alloy Stamping Technology (FAST) towards automotive applications: experimental studies

Abstract

In order to improve fuel efficiency and reduce carbon emissions for the automotive industry, a novel forming technology Fast light alloy stamping technology (FAST) for high and ultra-high strength aluminium alloy thin wall components (such as AA7075) was developed with experimental studies in this thesis. The process consists of: rapid heating, forming and in-die quenching, and incubation. A hot Stamping Simulator tool set to study FAST was successfully developed and manufactured to work in conjunction with the Gleeble 3800 thermo-mechanical testing machine. Based on this Hot Stamping Simulator, the effect of forming parameters on the formability of material and post-form strength have been studied for AA7075 2 mm blank. The effects of contact pressure, lubricant, and tool material on the Interfacial heat transfer coefficient (IHTC) have also been studied, and a mathematical model was developed in order to calculate the quenching time, predict post form strength and optimise the tool design to secure a high quenching rate, enabling the full post-form strength to be retained. Verification tests for the FAST process utilising AA7075 2 mm blank were conducted by forming U-shape and M-shape components. A standard testing procedure was developed for different materials and manufacturer requirements and was verified by studying 6 test cases. Finally, as a new forming process, conclusions and recommendations are made outlining additional factors to be studied to enable the FAST process to be adopted in an industrial environment.