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<p>One of the main limitations of 6000 series aluminum alloys in industrial forming is their low formability at ambient temperature. This study presents a novel experimental–numerical approach to enhance and characterize the formability of annealed AA6061 alloy under complex stress states using electric current. Hydraulic bulge tests were conducted on equibiaxial, circular notch, and oval notch specimens with and without electric current. To isolate athermal mechanisms, surface temperature was monitored during forming, confirming negligible Joule heating. The results showed that electric current increased equivalent plastic strain by 18.18% in uniaxial, 17.64% in oval notch, 17.31% in circular notch, and 10.71% in equibiaxial samples. Using Abaqus FE software, the MMC3 ductile fracture criterion was calibrated and validated for both current conditions. The fracture envelope revealed that electroplastic enhancement decreases with increasing stress triaxiality. Validation against experimental fracture displacements showed errors below 7.5%, confirming the predictive accuracy of the model. This study provides new insights into the role of stress triaxiality and Lode angle in electroplastic deformation, bridging the gap between simple tensile tests and real-world multiaxial forming. The findings offer practical implications for electrically assisted forming of lightweight alloys in automotive and aerospace applications, where complex stress states are prevalent.</p>

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Investigating the electroplastic effect on ductile fracture behavior of annealed AA6061 alloy sheet for formability improvement under complex stress States

  • 期刊论文

  • 发表日期：

    2025年12月1日

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  • Amirhesam Farkhondeh,
  • Mohammad Bakhshi-Jooybari,
  • Hamid Gorji,
  • Mohammad Javad Mirnia

摘要

One of the main limitations of 6000 series aluminum alloys in industrial forming is their low formability at ambient temperature. This study presents a novel experimental–numerical approach to enhance and characterize the formability of annealed AA6061 alloy under complex stress states using electric current. Hydraulic bulge tests were conducted on equibiaxial, circular notch, and oval notch specimens with and without electric current. To isolate athermal mechanisms, surface temperature was monitored during forming, confirming negligible Joule heating. The results showed that electric current increased equivalent plastic strain by 18.18% in uniaxial, 17.64% in oval notch, 17.31% in circular notch, and 10.71% in equibiaxial samples. Using Abaqus FE software, the MMC3 ductile fracture criterion was calibrated and validated for both current conditions. The fracture envelope revealed that electroplastic enhancement decreases with increasing stress triaxiality. Validation against experimental fracture displacements showed errors below 7.5%, confirming the predictive accuracy of the model. This study provides new insights into the role of stress triaxiality and Lode angle in electroplastic deformation, bridging the gap between simple tensile tests and real-world multiaxial forming. The findings offer practical implications for electrically assisted forming of lightweight alloys in automotive and aerospace applications, where complex stress states are prevalent.