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<p>Friction stir welding (FSW) was employed to fabricate tailored blank components, followed by single point incremental forming (SPIF) for further shaping. A three-layer laminate composed of AA6061 aluminum and DP980 steel was lap welded, and the specimen with optimal forming conditions was identified through microstructural analysis, including intermetallic compound (IMC) formation, lap shear strength, and temperature distribution during welding. The laminates then underwent SPIF in two phases: first achieving a deformation depth of 4.65 cm, then maintaining deformation until fracture. Optimization of forming depth, minimum thickness, and springback was carried out by varying SPIF parameters such as die angle, tool diameter, step size, spinning speed, and transverse speed. Finite Element Method (FEM) modeling was utilized to simulate the FSW and SPIF processes, confirming results with experimental data. Key variables affecting minimum thickness and springback were identified, with step size and wall angle being the most influential. Given the deformability of the base materials, a considerable maximum deformation depth of 6.67 cm, was reached in the SPIF process. An average thickness reduction strain of 85% was achieved in the upper aluminum part, which was excessively large and incompatible with the forming limit diagram. This significant reduction indicated potential volume loss, and the observed strains were influenced by localized deformation under specific loading conditions, leading to unbalanced strain behavior.</p>

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Incremental forming of friction stir welded three-layered AA6061/DP980 steel/AA6061 tailored blanks considering effective parameters on both processes

  • 期刊论文

  • 发表日期：

    2025年8月5日

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  • Akbar Hosseini

摘要

Friction stir welding (FSW) was employed to fabricate tailored blank components, followed by single point incremental forming (SPIF) for further shaping. A three-layer laminate composed of AA6061 aluminum and DP980 steel was lap welded, and the specimen with optimal forming conditions was identified through microstructural analysis, including intermetallic compound (IMC) formation, lap shear strength, and temperature distribution during welding. The laminates then underwent SPIF in two phases: first achieving a deformation depth of 4.65 cm, then maintaining deformation until fracture. Optimization of forming depth, minimum thickness, and springback was carried out by varying SPIF parameters such as die angle, tool diameter, step size, spinning speed, and transverse speed. Finite Element Method (FEM) modeling was utilized to simulate the FSW and SPIF processes, confirming results with experimental data. Key variables affecting minimum thickness and springback were identified, with step size and wall angle being the most influential. Given the deformability of the base materials, a considerable maximum deformation depth of 6.67 cm, was reached in the SPIF process. An average thickness reduction strain of 85% was achieved in the upper aluminum part, which was excessively large and incompatible with the forming limit diagram. This significant reduction indicated potential volume loss, and the observed strains were influenced by localized deformation under specific loading conditions, leading to unbalanced strain behavior.