none

Weight reduction is a hot topic in automotive industry. Both the applications of tube hydroforming technique and magnesium alloys offer a large potential for reducing the weight of automotive components. In this research, the relationship between forming pressure and bulge height, the maximum forming pressure and the forming limit during the tube hydraulic bulging process are first analysed. A self-designed warm hydraulic bulge forming equipment and the seamlessly extruted magnesium alloy AZ61 tubes, are used for carrying out a series of warm hydraulic bulge tests, and discussing the formalibility of the magnesium tubes at various temperatures. Furthermore, the flow stress curves are determined by the mathematical model in this paper with the bulge forming test results. Then the validity of the analytical model is verified by comparing the forming pressure and bulge height between analytical and experimental values.

Magnesium alloy tubes have good formability at elevated temperatures. In this study, a finite element code DEFORM 3D is used to simulate the result of T-shape hydroforming at working temperatures 150¢J and 250¢J with magnesium alloy AZ61 tubes and then conducts the hydroforming experiments. By modifying the loading paths, products with uniform thickness and branch height are obtained 49mm. The results of simulation are compared with the experimental results to verify the validity of this modeling. On the other hand, the effects of the die fillet radius on tube formability during y-shape hydroforming are discussed. With the right die fillet radius r1¡×10mm and the left die fillet radius r2¡×30mm, a better formability of the tube is obtained.

Laboratory-scale extrusion facilitated a parametric study of the metal extrusion process under controlled conditions. Hot extrusion experiments were performed on billets of both aluminum Al1100 as well as, magnesium alloys AZ61 and AM30. Tests were designed and executed with the purpose of recording load and temperature data to validate full-scale thermo-mechanical simulations performed with the commercial code HyperXtrude. Various aspects of flat die and conical die extrusion were observed, studied and modeled with the code. Conventional sine hyperbolic inverse material model was used in the simulations due to present limitations of HyperXtrude. Although this model showed a perfect viscoplastic response at constant temperature and strain rate, by proper changes in the material parameters the model captured the stress softening response characteristic of dynamic recrystallization in magnesium alloys, as shown for the case of AZ61. A framework is also presented for designing and understanding hot extrusion experiments and simulation boundary conditions.

This master’s thesis is dealing with low-fatigue behavior of magnesium alloy AZ61, prepared via squeeze casting method. The main aim of this work was to obtain the basic mechanical properties as well as the low cycle fatigue data. Additional metallographical evaluation of microstructure and fractographical analysis after fatigue tests was made.

Microstructure and mechanical properties of AZ61 magnesium alloy in cast condition and after solution annealing were compared. The compare of mechanical properties of alloy, their hardness and microanalysis of occurring phases are included in this work. For compare has been used a light microscopy, tensile test, hardness measurements and scanning electron microscopy.

O presente trabalho estuda a conformação da liga de magnésio AZ61 pelos processos de extrusão direta e forjamento, ambos a quente. No processo de extrusão, são submetidos à conformação corpos-de-prova da liga de magnésio AZ61 nos estados fundido e recristalizado. As geometrias de ferramenta são variadas e a influência destas variações sobre a força de processamento e propriedades mecânicas e microestrutura do material são analisada. Demonstra-se que a liga no estado inicialmente recristalizado tem propriedades mecânicas finais superiores à liga inicialmente fundida, embora demande de maior força de processamento. Demonstra-se também que a geometria de ferramenta tem influência sobre as respostas mecânicas obtidas das peças após extrusão. Referente ao processo de forjamento, a liga de magnésio AZ61 é processada apenas no estado recristalizado, variando-se a temperatura e o número de tapas de forjamento. Foi avaliada a influência destas variações de processo nas propriedades mecânicas finais da peça. Ao fim, percebe-se que ao se forjar as peças com múltiplas etapas de forjamento e temperaturas decrescentes, impede-se a recristalização do material, alcançando alto encruamento dos grãos, o que gera, na peça final, propriedades mecânicas superiores ao processo convencional. / This thesis studies the deformation of a magnesium alloy AZ61 by forward extrusion and forging processes, at elevated temperatures. In the extrusion process, the samples were deformed in as cast and recrystallized conditions. The tools geometries were variated and the influences on processing force, mechanical properties and material microstructure were analyzed. Was found that the recrystallized samples have better mechanical properties than as cast samples, after extruded, although it requires more processing force. Also was found that the tool geometry influences on mechanical properties and microstructure of extruded magnesium alloy. Relatively to the forging process, magnesium alloy AZ61 was processed only in the recrystallized state, varying the process temperature and the number of forging steps. Aimed to evaluate the process variations influences on the mechanical properties and microstructure of the final parts. At the end, was observed that when forging parts with multi-step forging and decreasing temperatures, to prevent recrystallization of the material, achieving high strain hardening of the grains, which results in final part with superior mechanical properties to the conventional process.

O presente trabalho estuda a conformação da liga de magnésio AZ61 pelos processos de extrusão direta e forjamento, ambos a quente. No processo de extrusão, são submetidos à conformação corpos-de-prova da liga de magnésio AZ61 nos estados fundido e recristalizado. As geometrias de ferramenta são variadas e a influência destas variações sobre a força de processamento e propriedades mecânicas e microestrutura do material são analisada. Demonstra-se que a liga no estado inicialmente recristalizado tem propriedades mecânicas finais superiores à liga inicialmente fundida, embora demande de maior força de processamento. Demonstra-se também que a geometria de ferramenta tem influência sobre as respostas mecânicas obtidas das peças após extrusão. Referente ao processo de forjamento, a liga de magnésio AZ61 é processada apenas no estado recristalizado, variando-se a temperatura e o número de tapas de forjamento. Foi avaliada a influência destas variações de processo nas propriedades mecânicas finais da peça. Ao fim, percebe-se que ao se forjar as peças com múltiplas etapas de forjamento e temperaturas decrescentes, impede-se a recristalização do material, alcançando alto encruamento dos grãos, o que gera, na peça final, propriedades mecânicas superiores ao processo convencional. / This thesis studies the deformation of a magnesium alloy AZ61 by forward extrusion and forging processes, at elevated temperatures. In the extrusion process, the samples were deformed in as cast and recrystallized conditions. The tools geometries were variated and the influences on processing force, mechanical properties and material microstructure were analyzed. Was found that the recrystallized samples have better mechanical properties than as cast samples, after extruded, although it requires more processing force. Also was found that the tool geometry influences on mechanical properties and microstructure of extruded magnesium alloy. Relatively to the forging process, magnesium alloy AZ61 was processed only in the recrystallized state, varying the process temperature and the number of forging steps. Aimed to evaluate the process variations influences on the mechanical properties and microstructure of the final parts. At the end, was observed that when forging parts with multi-step forging and decreasing temperatures, to prevent recrystallization of the material, achieving high strain hardening of the grains, which results in final part with superior mechanical properties to the conventional process.

O presente trabalho estuda a conformação da liga de magnésio AZ61 pelos processos de extrusão direta e forjamento, ambos a quente. No processo de extrusão, são submetidos à conformação corpos-de-prova da liga de magnésio AZ61 nos estados fundido e recristalizado. As geometrias de ferramenta são variadas e a influência destas variações sobre a força de processamento e propriedades mecânicas e microestrutura do material são analisada. Demonstra-se que a liga no estado inicialmente recristalizado tem propriedades mecânicas finais superiores à liga inicialmente fundida, embora demande de maior força de processamento. Demonstra-se também que a geometria de ferramenta tem influência sobre as respostas mecânicas obtidas das peças após extrusão. Referente ao processo de forjamento, a liga de magnésio AZ61 é processada apenas no estado recristalizado, variando-se a temperatura e o número de tapas de forjamento. Foi avaliada a influência destas variações de processo nas propriedades mecânicas finais da peça. Ao fim, percebe-se que ao se forjar as peças com múltiplas etapas de forjamento e temperaturas decrescentes, impede-se a recristalização do material, alcançando alto encruamento dos grãos, o que gera, na peça final, propriedades mecânicas superiores ao processo convencional. / This thesis studies the deformation of a magnesium alloy AZ61 by forward extrusion and forging processes, at elevated temperatures. In the extrusion process, the samples were deformed in as cast and recrystallized conditions. The tools geometries were variated and the influences on processing force, mechanical properties and material microstructure were analyzed. Was found that the recrystallized samples have better mechanical properties than as cast samples, after extruded, although it requires more processing force. Also was found that the tool geometry influences on mechanical properties and microstructure of extruded magnesium alloy. Relatively to the forging process, magnesium alloy AZ61 was processed only in the recrystallized state, varying the process temperature and the number of forging steps. Aimed to evaluate the process variations influences on the mechanical properties and microstructure of the final parts. At the end, was observed that when forging parts with multi-step forging and decreasing temperatures, to prevent recrystallization of the material, achieving high strain hardening of the grains, which results in final part with superior mechanical properties to the conventional process.

This work deals with the corrosion protection of magnesium alloy AZ31, AZ61, AZ91 using fluoride conversion coating prepared from Na[BF4] melt. The theoretical part describes the properties of magnesium alloys, the recent results of fluoride conversion coatings preparation and analysis of the available literature about the properties of salt Na[BF4] and its decomposition products. The experimental part was devided into two main sections. The first deals with the corrosion resistance of the treated magnesium alloys (AZ31, AZ61, AZ91 and AZ91 annealed) in the Na[BF4] melt. Corrosion resistance was tested using potentiodynamic tests and tests in the corrosion chamber. In the second part, the mechanism has been studied for preparing fluoride conversion coating, where it was shown that in air-free atmosphere the oxidizing agent in the process is boron, which is reduced from BIII to B0, and thereby enables the fluoride conversion coating.