Numerical/experimental investigation of the effect of the laser treatment on the thickness distribution of a magnesium superplastically formed part

doi:10.1007/s40436-024-00497-x

Advances in Manufacturing ›› 2025, Vol. 13 ›› Issue (2): 284-302.doi: 10.1007/s40436-024-00497-x

Numerical/experimental investigation of the effect of the laser treatment on the thickness distribution of a magnesium superplastically formed part

Angela Cusanno¹, Pasquale Guglielmi¹, Donato Sorgente^1,2, Gianfranco Palumbo¹

1. Department of Mechanics, Mathematics and Management, Politecnico di Bari, Viale Japigia 182, Bari 70126, Italy;
2. School of Engineering, Università degli Studi della Basilicata, Potenza, Italy

收稿日期:2023-09-08 修回日期:2023-11-21 发布日期:2025-05-16
通讯作者: Pasquale Guglielmi,E-mail:pasquale.guglielmi@poliba.it E-mail:pasquale.guglielmi@poliba.it
作者简介:Angela Cusanno is a Research Associate at the Polytechnic University of Bari. Her research interests include sheet metal forming of lightweight alloys using flexible media (gas forming, hydroforming using oil and magnetorheological fluids, incremental forming) and innovative methodologies for the mechanical characterization of Aluminum alloys based on the local modification of their mechanical properties.
Pasquale Guglielmi is a Research Associate at the Polytechnic University of Bari. His research interests include sheet metal forming and foundry techniques both from an experimental and numerical point of view. In addition, it conducts metal mater ial characterization activities through both destructive testing and metallographic investigation.
Donato Sorgente is an associate professor at the Polytechnic University of Bari. His research interests are mainly related to non-conventional materials processing technologies with focus on warm and hot sheet metal forming of light metal alloys, innovative techniques for the mechanical and technological characterization of materials, laser welding technology and laser heat treatments of steels. He is involved in several research projects related to those topics and funded both by private companies and by public institutions.
Gianfranco Palumbo is a Full Professor and doctoral supervisor at the Polytechnic University of Bari. His research interests can be divided into 3 interconnected areas: (1) mechanical, thermo-mechanical and technological material characterization; (2) investigation about conventional and innovative sheet metal forming processes; (3) finite element simulation of surface treatments and metal forming processes. The investigation of manufacturing processes is conducted using a numerical/experimental approach (implementation of mechanical, thermo-mechanical and technological data form the material characterization and experiments for validation purposes) and it is aimed at identifying limits, working conditions and optimal ranges of process parameters.
基金资助:
This paper is founded by the European Union-Next Generation EU (National Sustainable Mobility Center (Grant No. CN00000023), Italian Ministry of University and Research Decree (Grant No. 1033-17/06/2022), Spoke 11–Innovative Materials & Lightweighting. The opinions expressed are those of the authors only and should not be considered as representative of the European Union or the European Commission’s official position. Neither the European Union nor the European Commission can be held responsible for them. The authors also wish to thank Dr. Antonio Piccininni for his support.

Numerical/experimental investigation of the effect of the laser treatment on the thickness distribution of a magnesium superplastically formed part

Angela Cusanno¹, Pasquale Guglielmi¹, Donato Sorgente^1,2, Gianfranco Palumbo¹

1. Department of Mechanics, Mathematics and Management, Politecnico di Bari, Viale Japigia 182, Bari 70126, Italy;
2. School of Engineering, Università degli Studi della Basilicata, Potenza, Italy

Received:2023-09-08 Revised:2023-11-21 Published:2025-05-16
Contact: Pasquale Guglielmi,E-mail:pasquale.guglielmi@poliba.it E-mail:pasquale.guglielmi@poliba.it
Supported by:
This paper is founded by the European Union-Next Generation EU (National Sustainable Mobility Center (Grant No. CN00000023), Italian Ministry of University and Research Decree (Grant No. 1033-17/06/2022), Spoke 11–Innovative Materials & Lightweighting. The opinions expressed are those of the authors only and should not be considered as representative of the European Union or the European Commission’s official position. Neither the European Union nor the European Commission can be held responsible for them. The authors also wish to thank Dr. Antonio Piccininni for his support.

摘要/Abstract

摘要： The growing need for high-performance components in terms of shape and mechanical properties encourages the adoption of integrated technological solutions. In the present work, a novel methodology for affecting the superplastic behaviour and, in turn, the thickness distribution of magnesium alloy components is proposed. Through heat treatments using a CO₂ laser, the grain size was locally changed, thus modifying the superplastic behaviour in a predefined area of the blank. Both the grain coarsening produced by the laser heat treatment and the superplastic forming of the heat treated blank were simulated using a finite element model, which allowed to set the related process parameters for the manufacturing of the investigated case study (a truncated cone). The thermal finite element model of the laser heat treatment, calibrated using the experimental temperature evolutions acquired in specific areas during the heat treatment, was used to evaluate the influence of process parameters on the grain size evolution. The laser heat treatment was able to significantly promote the grain growth, increasing the mean grain size from about 8 μm to twice (about 17 μm). The resulting grain size distributions were implemented in the mechanical finite element model of the superplastic forming process and the combination of laser parameters which allowed to obtain the most uniform thickness distribution on the final component was finally experimentally reproduced and measured for validation purposes. Even in the case of the laboratory scale application, characterised by quite small dimensions, the proposed approach revealed to be effective, to improving the thinning factor (t_MIN/t_AVG) of the formed part from 0.85 to 0.89, and providing an increase in the thickness uniformity of about 4.7%.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00497-x

关键词: Laser heat treatment, Grain size, Super plastic behaviour, Finite element, Magnesium alloys, Thickness uniformity

Abstract: The growing need for high-performance components in terms of shape and mechanical properties encourages the adoption of integrated technological solutions. In the present work, a novel methodology for affecting the superplastic behaviour and, in turn, the thickness distribution of magnesium alloy components is proposed. Through heat treatments using a CO₂ laser, the grain size was locally changed, thus modifying the superplastic behaviour in a predefined area of the blank. Both the grain coarsening produced by the laser heat treatment and the superplastic forming of the heat treated blank were simulated using a finite element model, which allowed to set the related process parameters for the manufacturing of the investigated case study (a truncated cone). The thermal finite element model of the laser heat treatment, calibrated using the experimental temperature evolutions acquired in specific areas during the heat treatment, was used to evaluate the influence of process parameters on the grain size evolution. The laser heat treatment was able to significantly promote the grain growth, increasing the mean grain size from about 8 μm to twice (about 17 μm). The resulting grain size distributions were implemented in the mechanical finite element model of the superplastic forming process and the combination of laser parameters which allowed to obtain the most uniform thickness distribution on the final component was finally experimentally reproduced and measured for validation purposes. Even in the case of the laboratory scale application, characterised by quite small dimensions, the proposed approach revealed to be effective, to improving the thinning factor (t_MIN/t_AVG) of the formed part from 0.85 to 0.89, and providing an increase in the thickness uniformity of about 4.7%.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00497-x

Key words: Laser heat treatment, Grain size, Super plastic behaviour, Finite element, Magnesium alloys, Thickness uniformity

Angela Cusanno, Pasquale Guglielmi, Donato Sorgente, Gianfranco Palumbo. Numerical/experimental investigation of the effect of the laser treatment on the thickness distribution of a magnesium superplastically formed part[J]. Advances in Manufacturing, 2025, 13(2): 284-302.

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Numerical/experimental investigation of the effect of the laser treatment on the thickness distribution of a magnesium superplastically formed part

Numerical/experimental investigation of the effect of the laser treatment on the thickness distribution of a magnesium superplastically formed part

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