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Metals
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Plasticity and Metal Forming
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Plasticity and Metal Forming

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Metal Casting, Forming and Heat Treatment".

Deadline for manuscript submissions: closed (15 May 2025) | Viewed by 8832

Special Issue Editors

Dr. Gaoshen Cai

E-Mail Website
Guest Editor
School of Mechanical Engineering, Zhejiang Sci-Tech University, Hangzhou, 310018, China
Interests: Hydroforming; Plastic forming; Formability; Additive manufacturing
Dr. Yao Wang

E-Mail Website
Guest Editor
School of Mechanical Engineering, Hebei University of Technology, Tianjin 300400, China
Interests: plasticity and metal forming; fibre metal laminates; drawing forming; in-situ composite

Special Issue Information

Dear Colleagues,

Plasticity and metal forming are important methods of metal processing in the modern manufacturing industry. The progress of plasticity and metal forming and processing, including the control and characterization of materials in all processing steps and their final performance analysis, is the scope of this Special Issue. Nowadays, with the extensive use of new materials and composite materials in the manufacturing industry, the requirements for plasticity and metal forming processes are continuously increasing to meet the requirements of lightweight products. At the same time, breakthroughs have been made in the development of a series of technologies related to plasticity and metal forming, such as numerical control processing, artificial intelligence, and integrated manufacturing, and new technologies and processes for plasticity and metal forming are constantly emerging.

This Special Issue welcomes articles that focus on new plasticity and metal processing and manufacturing methods and their impact on the performance of end products. Fully controllable fast and low-cost processes especially remain of interest, with a high implementation potential in plasticity and metal forming that allows producing high-performance products.

Dr. Gaoshen Cai
Dr. Yao Wang
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Metals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • plasticity
  • metal forming
  • hydroforming
  • stamping forming
  • deformation mechanism
  • difficult-to-deform materials
  • compound material
  • structural characterization
  • aluminum alloy

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Published Papers (7 papers)

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Research

17 pages, 16535 KiB  
Article
The Annealing Effect on Microstructure and Texture Evolution of Spun Al-Mg Alloy Tubes with Cross Inner Ribs
by Ke Yuan, Hongsheng Chen, Fei Chai and Zhuoran Wang
Metals 2025, 15(4), 441; https://doi.org/10.3390/met15040441 - 15 Apr 2025
Viewed by 209
Abstract
Tubes with a cross inner rib exhibit significant internal residual stresses after spinning, which seriously affects their properties. The recrystallization and texture evolution of the tube at different annealing temperatures were investigated. The results showed that severe plastic deformation occurred during the spinning [...] Read more.
Tubes with a cross inner rib exhibit significant internal residual stresses after spinning, which seriously affects their properties. The recrystallization and texture evolution of the tube at different annealing temperatures were investigated. The results showed that severe plastic deformation occurred during the spinning process, with an average grain size of 10.94 μm and a residual compressive stress of −75 MPa. The annealing treatment increased the yield strength and elongation but decreased the ultimate tensile strength. At 290 °C, the residual stress decreased to −50.1 MPa, the grain size was refined to 5.9 μm, the β-fiber structure was retained, and excellent mechanical properties were obtained, with a yield strength of 106.22 MPa, an elongation of 42.43%, and an ultimate tensile strength of 378.55 MPa. At 350 °C, the grain size increased to 7.2 μm, the β-fiber structure disappeared, the mechanical properties decreased, and the residual stress was further reduced to −24.01 MPa. The fracture mode after annealing was a ductile fracture. Full article
(This article belongs to the Special Issue Plasticity and Metal Forming)
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25 pages, 7603 KiB  
Article
Analysis of Nonuniform Deformation in Aluminum Wires Under Varying Torsional Loads Using EBSD Measurement and Multiscale Crystal Plasticity
by Mohammad Javad Rezaei, Fernando Warchomicka, Maria Cecilia Poletti, Mojtaba Pourbashiri and Mohammad Sedighi
Metals 2025, 15(2), 145; https://doi.org/10.3390/met15020145 - 30 Jan 2025
Viewed by 954
Abstract
Computational crystal plasticity (CP) models are widely utilized in the literature to analyze the deformation responses of materials at the microstructural level under macroscopic loading conditions. The challenge of connecting changes in texture with macroscopic loading can be effectively addressed through a multiscale [...] Read more.
Computational crystal plasticity (CP) models are widely utilized in the literature to analyze the deformation responses of materials at the microstructural level under macroscopic loading conditions. The challenge of connecting changes in texture with macroscopic loading can be effectively addressed through a multiscale CPFE approach. This research focuses on bridging changes in texture and macroscopic loading in pure aluminum wire under torsional loading through the innovative use of the multiscale CP finite element simulation approach and integration with experimental data. The study deals with the effects of the initial average grain size, strain rate, and strains on microstructural evolution at room temperature and mechanical properties. An inhomogeneous initial texture for an as-received specimen was extracted using EBSD measurements and assigned to a CP code to solve the multiscale CPFEM simulations. Changes in texture obtained from pole figures indicated that the A (111¯)[11¯0],B (112¯)[11¯0], B¯ (1¯1¯2)[1¯10], C (100)[01¯1], A1∗ (111¯)[21¯1], and A2∗(11¯1) [2¯1¯1] components had the highest frequencies among the torsional tests. The analysis of the resulting texture through the Taylor factor (TF) revealed that the average TF distribution increased from 2.65 to 3.04 when the local strain increased from 0.5 to 2.5 revolutions. Furthermore, an increase in the number of rotations from 0.5 to 2.5 resulted in an 11% increase in average hardness near the outer surface of specimens with an average grain size of 55 µm. Full article
(This article belongs to the Special Issue Plasticity and Metal Forming)
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15 pages, 8486 KiB  
Article
Interlayer Friction Mechanism and Scale Effects in Ultra-Thin TA1 Titanium Alloy/Carbon Fiber-Reinforced Plastic Laminates
by Quanda Zhang, Zeen Liu, Guopeng Song, Fuzhen Sun, Zizhi Liu, Xiaoxu Li and Wengang Chen
Metals 2024, 14(12), 1369; https://doi.org/10.3390/met14121369 - 30 Nov 2024
Viewed by 631
Abstract
Fiber metal laminates (FMLs) are a novel lightweight composite material, predominantly utilized in the aerospace sector for large-scale components like skin panels and fuselages. However, research on FMLs in the microsystem domain remains limited. Additionally, they are influenced by scale effects, rendering macroscopic [...] Read more.
Fiber metal laminates (FMLs) are a novel lightweight composite material, predominantly utilized in the aerospace sector for large-scale components like skin panels and fuselages. However, research on FMLs in the microsystem domain remains limited. Additionally, they are influenced by scale effects, rendering macroscopic forming theories inadequate for microforming applications. The application of ultra-thin fiber metal laminates in the microsystem field is hindered by this constraint. This paper investigates the friction performance of ultra-thin TA1 titanium alloy/carbon fiber-reinforced plastic (CFRP) laminates at the microscale. The content of the epoxy resin used is 38.0 ± 3.0%. Friction tests on ultra-thin TA1/CFRP laminates were conducted based on the Striebeck friction theory model. The effects of factors such as the weaving method, ply angle, normal force, tensile speed, and temperature on friction performance are explored in the study. Furthermore, the influences of geometric scale and grain scale on friction performance are examined. Geometric scale effects indicate that an increase in laminate width leads to an increase in the friction coefficient. Grain-scale effects demonstrate that as grain size increases, the friction coefficient also increases, attributed to reduced grain boundaries, increased twinning, and increased surface roughness of the metal. Finally, surface morphology analysis of the metal and fiber after friction tests further confirms the influence of grain size on the friction coefficient. Through detailed experimental design, result analysis and graphical representation, this paper provides a scientific basis for understanding and predicting the friction behavior of ultra-thin TA1/CFRP laminates. Full article
(This article belongs to the Special Issue Plasticity and Metal Forming)
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14 pages, 2171 KiB  
Article
Enhanced Mechanical Properties of Ceramic Rod-Reinforced TWIP Steel Composites: Fabrication, Microstructural Analysis, and Heat Treatment Evaluation
by Guojin Sun, Shengzhi Zhu, Zhenggui Li and Qi Wang
Metals 2024, 14(9), 1083; https://doi.org/10.3390/met14091083 - 21 Sep 2024
Viewed by 1023
Abstract
This study investigates the development and characterization of ceramic rod-reinforced TWIP (twinning-induced plasticity) steel matrix composites, produced using the lost foam casting technique. Mechanical tests revealed a substantial improvement in both flexural strength and ductility, with the composite demonstrating more than double the [...] Read more.
This study investigates the development and characterization of ceramic rod-reinforced TWIP (twinning-induced plasticity) steel matrix composites, produced using the lost foam casting technique. Mechanical tests revealed a substantial improvement in both flexural strength and ductility, with the composite demonstrating more than double the strength of unreinforced TWIP steel. Furthermore, a simple low-temperature heat treatment further enhanced these properties, increasing the flexural strength of the composite to 1023 MPa while also improving its ductility. The improvement in mechanical performance is attributed to the formation of additional twins in the TWIP steel matrix during deformation following heat treatment, which resulted in further strengthening of the matrix. Full article
(This article belongs to the Special Issue Plasticity and Metal Forming)
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Graphical abstract

17 pages, 23317 KiB  
Article
Plastic Shakedown Behavior and Deformation Mechanisms of Ti17 Alloy under Long Term Creep–Fatigue Loading
by Jianguo Wang, Tongchi Man, Dong Liu, Zhihong Zhang, Chi Zhang and Yuxiang Sun
Metals 2024, 14(7), 743; https://doi.org/10.3390/met14070743 - 22 Jun 2024
Viewed by 1531
Abstract
Ti17 alloy is mainly used to manufacture aero-engine discs due to its excellent properties such as high strength, toughness and hardenability. It is often subjected to creep–fatigue cyclic loading in service environments. Shakedown theory describes the state in which the accumulated plastic strain [...] Read more.
Ti17 alloy is mainly used to manufacture aero-engine discs due to its excellent properties such as high strength, toughness and hardenability. It is often subjected to creep–fatigue cyclic loading in service environments. Shakedown theory describes the state in which the accumulated plastic strain of the material stabilizes after several cycles of cyclic loading, without affecting its initial function and leading to failure. This theory includes three behaviors: elastic shakedown, plastic shakedown and ratcheting. In this paper, the creep–fatigue tests (CF) were conducted on Ti17 alloy at 300 °C to study its shakedown behavior under creep–fatigue cyclic loading. Based on the plasticity–creep superposition model, a theory model that accurately describes the shakedown behavior of Ti17 alloy was constructed, and ABAQUS finite element software was used to validate the accuracy of the model. TEM analysis was performed to observe the micro-mechanisms of shakedown in Ti17 alloy. The results reveal that the Ti17 alloy specimens exhibit plastic shakedown behavior after three cycles of creep–fatigue loading. The established finite element model can effectively predict the plastic shakedown process of Ti17 alloy, with a relative error between the experimental and simulation results within 4%. TEM results reveal that anelastic recovery controlled by dislocation bending and back stress hardening caused by inhomogeneous deformation are the main mechanisms for the plastic shakedown behavior of Ti17 alloy. Full article
(This article belongs to the Special Issue Plasticity and Metal Forming)
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15 pages, 7711 KiB  
Article
Optimization of Processing Parameters of Aluminum Alloy Cylindrical Parts Based on Response Surface Method during Hydromechanical Deep Drawing
by Yufeng Pan and Gaoshen Cai
Metals 2023, 13(8), 1406; https://doi.org/10.3390/met13081406 - 6 Aug 2023
Cited by 4 | Viewed by 1756
Abstract
Aluminum alloy has been proposed as one of the next generation of lightweight body structure materials, which is widely used in the main components of the aerospace field. In order to realize efficient and accurate forming of aluminum alloy cylindrical parts, the response [...] Read more.
Aluminum alloy has been proposed as one of the next generation of lightweight body structure materials, which is widely used in the main components of the aerospace field. In order to realize efficient and accurate forming of aluminum alloy cylindrical parts, the response surface method combined with finite element simulation was used to optimize the key processing parameters during the hydromechanical deep drawing process. Three processing parameters of friction coefficient, pressure rate, and fillet radius of the die were selected as the optimization variables, and the maximum thinning rate of cylindrical parts was selected as the optimization evaluation index. The Box–Behnken design was selected to design the experiment scheme. A quadratic response model between the maximum thinning rate and the processing parameters was established by the response surface analysis software Design Expert for experimental design and data analysis. The optimal processing parameter combination was obtained through this model. The results show that the optimal conditions of maximum thinning rate can be met when the pressure rate is 11.6 MPa/s, the friction coefficient is 0.15, and the fillet radius of the die is 8 mm. Finally, the experimental verification was carried out by using the optimized combination of process parameters. It was found that the error between the experimental results and the predicted simulation results was within 5%, and the cylindrical parts which met the quality requirements were finally formed. Full article
(This article belongs to the Special Issue Plasticity and Metal Forming)
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19 pages, 9547 KiB  
Article
The Experimental Study on the Mechanical Properties of Fiber-Reinforced Metal Laminates Using an Innovative Heat-Solid Integrated Forming Technology
by Quanda Zhang, Fuzhen Sun, Yinuo Ma and Zhiying Sun
Metals 2023, 13(7), 1199; https://doi.org/10.3390/met13071199 - 28 Jun 2023
Cited by 3 | Viewed by 1652
Abstract
In the forming process of fiber-reinforced metal laminates (FMLs) product, the exploratory compound forming technology, including hot stamping of aluminum alloy and laying process of fiber prepreg which is named HFQ-FMLs was proposed to solve the puzzles such as weak rigidity, low strength [...] Read more.
In the forming process of fiber-reinforced metal laminates (FMLs) product, the exploratory compound forming technology, including hot stamping of aluminum alloy and laying process of fiber prepreg which is named HFQ-FMLs was proposed to solve the puzzles such as weak rigidity, low strength and integration deformation with large difficulty, and the feasibility and mechanical properties of the innovative forming process were studied. Firstly, based on the modified metal volume fraction formula, the theoretical values of the mechanical properties of the HFQ-FMLs plates were calculated. Compared with the experimental results, the minimum error is 1%, proving that the HFQ-FMLs technology scheme is feasible. Secondly, three kinds of metal sheets with different heat treatments and specimens by HFQ-FMLs were carried out for the tensile tests, the mechanical properties distributions were demonstrated, and the influence regularity of the strain rate and rolling direction on the stress analysis was considered at the same time. As can be seen from the distribution of yield strength and tensile strength, the yield stress of metal sheets obtained by HFQ-FMLs technology along the 45° is superior to the raw material and can increase by 46% under strain rate = 0.01 s−1. While, because the vacuum thermal curing treatment makes the aluminum alloy happen double aging, the metal sheet strength dropped, and the jointing strength between the metal and fiber prepreg became weak too, which made the strength limit of the new material improve weakly. Thirdly, the fractured style of the FMLs under different conditions was studied qualitatively. It is helpful to achieve the development rule of defects, optimize the craft route, and avoid deformation failure. Full article
(This article belongs to the Special Issue Plasticity and Metal Forming)
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