Studies on Formability and Deformation Behavior of Lightweight Alloys

Dear Colleagues,

Lightweight alloys, such as aluminum-, magnesium-, and titanium-based alloys, have garnered significant attention in modern engineering due to their exceptional strength-to-weight ratios, corrosion resistance, and potential for energy-efficient applications in the automotive, aerospace, and consumer electronics industries. However, their widespread adoption is often hindered by challenges related to formability and complex deformation behavior during manufacturing processes, such as stamping, forging, or extrusion. Understanding these characteristics is critical to optimizing production techniques, enhancing component performance, and reducing material waste. Formability refers to the ability of a material to undergo plastic deformation without failure, which is influenced by factors such as alloy composition, microstructure, and processing conditions. Lightweight alloys often exhibit limited ductility at room temperature, anisotropic behavior, and susceptibility to defects such as springback or wrinkling, complicating their shaping into intricate geometries. For instance, magnesium alloys, despite their low density, face challenges due to hexagonal close-packed (HCP) crystal structures, which restrict slip systems and lead to poor room-temperature formability. Similarly, high-strength aluminum alloys may suffer from reduced elongation, necessitating advanced forming strategies. Recent studies focus on characterizing deformation mechanisms through experimental and computational approaches. Advanced mechanical testing, including tensile, compression, and forming limit experiments, coupled with microstructural analysis via electron microscopy and X-ray diffraction, reveals insights into dislocation dynamics, twinning, and phase transformations. Finite element modeling (FEM) and crystal plasticity simulations further aid in predicting formability limits and optimizing process parameters. Additionally, innovative techniques, such as warm forming, hydroforming, or electromagnetic pulse forming, are being explored to enhance ductility by activating additional slip systems or mitigating residual stresses.

In this Special Issue, we welcome articles that focus on metal forming methods and their associated deformation processes and microstructural evolution. The studies that drive the fundamental understanding of lightweight alloy behavior and the development of processing routes are of particular interest, paving the way for next-generation, high-performance components.

Dr. Chunhui Liu
Guest Editor

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• metal forming
• constitutive modeling
• deformation mechanism
• microstructural evolution
• formability–performance synergy
• lightweight alloys
• forming defects
• precision forming