Process Design of Aluminum Tailor Heat Treated Blanks

Area of Science:

• Materials Science
• Manufacturing Engineering
• Automotive Engineering

Background:

• Growing demand for lightweight automotive components to reduce CO₂ and NOₓ emissions.
• Precipitation hardenable aluminum alloys offer a lightweight alternative to steel but have limited formability for complex parts.

Purpose of the Study:

• To present a holistic approach for designing the Tailor Heat Treated Blanks (THTB) process.
• To optimize the mechanical properties of aluminum alloys for enhanced formability in complex stamping operations.

Main Methods:

• Development of an innovative technology involving local heat treatment of blanks before forming (THTB).
• Holistic approach to design the THTB process, considering key influencing parameters.
• Simulation and experimental validation of the THTB process for complex forming operations.

Main Results:

• Accurate material property description is crucial for predicting the forming behavior of THTB.
• The THTB process enables the use of aluminum alloys in complex automotive parts.
• Demonstrated capability of the approach by comparing simulated and actual local blank thickness for a tailgate.

Conclusions:

• The THTB process is a viable technology for enhancing the formability of aluminum alloys.
• The presented holistic approach aids in the process development for complex forming operations.
• Successful application in automotive manufacturing contributes to lightweight construction and emission reduction.