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Commentary
In addition to being much better controlled and instrumented than plant-scale experiments, the mechanical testing laboratory is a much less expensive way to obtain data. The combined efforts of plant-scale and laboratory experimentation should lead to a fundamental understanding of hot deformation.
these processes sufficiently well so as to be able to optimize industrial hot-working processes to produce products with properties that meet customer needs. In this issue, the paper by McQueen provides a broad-brush view of the subtle complexity that must be tracked if one wants to understand how aluminum alloys respond to hot deformation conditions. The following five papers on the theme of hot deformation provide examples of work that will be presented at the up-
These papers fall into three general categories: constitutive equations or state variable equations that seek to express flow stress and work-hardening rate in terms of strain rate, temperature, and evolving microstructure; crystal plasticity simulations that use the kinetics of deformation at the slip-plane level to predict flow stress and texture evolution in a textured polycrystalline aggregate subjected to a given strain path; and finite-element modeling at length scales typical of industrial forming processes and products. A highlight of the meeting will be the confluence of the categories: state variable equations to describe plasticity at the level of a single grain incorporated into crystal plasticity calculations to predict the evolution of properties of a polycrystal and, finally, the incorporation of polycrystal plasticity in full three-dimensional simulations of hot deformation where the strain path imposed by the forming operation varies from point to point and is not known a priori. Combined finite-element modeling with crystal plasticity is making an impact not only in the simulation of industrial hotworking processes, but also in our ability to understand the origins of inhomogeneous deformation using finite-element models, where single grains are subdivided into many finite elements
and the properties of each are defined by crystal plasticity. An excellent example of the use of sophisticated and powerful modeling to understand recrystalization can be found in this issue in the paper by Engler and Vatne. In addition, the synergy of interdisciplanary teams is evident from the opening paper, by Hughes et al., which describes how a U.S. Department of Energy Center has brought together and coordinated the efforts of top researchers in the fields of plasticity, texture, microstructural characterization, and mathematical modeling. Superplastic forming is a small but growing subset of the hot-working activity in aluminum alloys. With superplastic forming, complex parts can be formed in a single operation, often in a manner that permits part consolidation and substantial cost savings. However, superplastic forming has historically been perceived as a slow process and, thus, not appealing for large-scale production. In the past decade, however, superplastic forming at strain rates high enough to be cost effective for largevolume production has been demonstrated using aluminum-matrix composites. These composites have a fine, stable grain size (see, for example, this issues overview by Mabuchi and Higashi). A particularly important advance in this
field is the development of fine grain sizes that are stable at elevated temperatures in conventional alloys. This can be accomplished with particular rolling and annealing schedules (see, for example, the article by Hughes et al.). The use of equal-channel angle pressing is an example of a hot-forming process that permits the development of fine grain sizes in conventional alloys with characteristics that are good for superplastic forming at high strain rates (see this issues article by Langdon et al.). As the goal of high-strain-rate superplasticity is realized, the possibility of the large tonnage production of complexly shaped parts using superplastic forming will become attractive. We hope you enjoy reading the excellent state-of-the-art articles that follow, especially since hot-deformation history dictates what can or cannot be accomplished in further processinga critical consideration as almost 80 percent of the aluminum products that we currently use depend on hot-deformation processes.
Thomas R. Bieler is an associate professor in the Department of Materials Science and Mechanics at Michigan State University and is the advisor to JOM from the Shaping and Forming Committee of the TMS Materials Processing & Manufacturing Division. Lawrence A. Lalli is with Alcoa Technical Center, and Stuart R. MacEwen is with Alcan International.
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