Damage behavior and performance analysis of Al5083 alloy in superplastic bulging

To evaluate the superplasticity of the Al5083 alloy, a comprehensive experimental and analytical approach was undertaken. Tensile tests with varying strain rates (0.0005 s-1, 0.001 s-1, 0.005 s-1, 0.01 s- 1) and free bulging tests (0.4 MPa, 0.7 MPa, 1.0 MPa, 1.3 MPa) at different pressures (450 degrees C, 480 degrees C, 510 degrees C) were conducted at multiple temperatures. The Hill-GTN damage model was initially implemented for the Al5083 alloy and calibrated through finite element parameter inverse analysis. The study underscores the robust predictive capability of the developed model in simulating the evolution of thickness distribution under biaxial stress conditions. But the predictions on forming time and dome height are not entirely accurate. Additionally, the impact of superplastic deformation on various material properties was explored, including an exponential relationship between the cavity volume fraction and strain, microstructural alterations, a diminished XRD diffraction peak strength, a notable 13 % decrement in microhardness, and a decrease in corrosion resistance. These insights have profound implications for the effective design and optimization of aluminum alloy superplastic forming processes.