Forming-Limit Diagrams for Magnesium AZ31B and ZEK100 Alloy Sheets at Elevated Temperatures

Modern design and manufacturing methodologies for magnesium (Mg) sheet panels require formability data for use in computer-aided design and computer-aided engineering tools. To meet this need, forming-limit diagrams (FLDs) for AZ31B and ZEK100 wrought Mg alloy sheets were developed at elevated temperatures for strain rates of 10−3 and 10−2 s−1. The elevated temperatures investigated range from 250 to 450 °C for AZ31B and 300 to 450 °C for ZEK100. The FLDs were generated using data from uniaxial tension, biaxial bulge, and plane-strain bulge tests, all carried out until specimen rupture. The unique aspect of this study is that data from materials with consistent processing histories were produced using consistent testing techniques across all test conditions. The ZEK100 alloy reaches greater major true strains at rupture, by up to 60%, than the AZ31B alloy for all strain paths at all temperatures and strain rates examined. Formability limits decrease only slightly with a decrease in temperature, less than 30% decrease for AZ31B and less than 35% decrease for ZEK100 as the temperature decreases from 450 to 300 °C. This suggests that forming processes at 250-300 °C are potentially viable for manufacturing complex Mg components.