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<p>The hot stamping of high strength 7xxx-series aluminum sheet provides near net-shape automotive components but requires specialized aging treatments to reach the target properties. Conventional approaches to determine the process window for solutionization heat treatments (SHT) of 7xxx-series aluminum seldom account for the forming strain, assume idealized processes that are not industrially-representative, and focus upon the strength response while overlooking the key role of bendability on crash performance. The current study develops a robust procedure to identify the hot forming process window for 7xxx series aluminum sheet with application to the recently commercialized automotive grade C7M7 alloy. The industrial hot stamping process was simulated in an automated test cell using solutionization temperatures of 473˚C and 495˚C for 3-to-15&#xa0;min using a fast-heating contact furnace. The influence of the non-isothermal forming strain was considered using flat blanks and interrupted plane strain Marciniak tests. The microstructural evolution during the aging and paint bake treatments was characterized using electrical conductivity and hardness tests. The post paint-baking properties were characterized using miniature tensile and VDA238-100 tight-radius bend tests. Relatively short SHT durations of 3-to-5&#xa0;min at both temperatures were found to produce similar properties. Accelerated aging kinetics and reduced peak hardness were observed as forming strain increased. For a forming strain of 25%, the UTS decreased approximately 5%, the total elongation decreased by 40%, and the plane strain bendability decreased by 25% compared to the blanks without forming strain. Property correlations were then developed to estimate tensile and fracture response. Demonstrator hat-channel rail parts were hot-stamped and the properties measured along different locations. Overall, the study elucidates the combined effects of hot forming and SHT parameters on the post-aging mechanical properties of hot stamped AA7xxx alloys, providing critical insight for component design and industrial production.</p>

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Effects of hot stamping process variables on aged product performance of 7xxx automotive aluminum sheet

  • 期刊论文

  • 发表日期：

    2026年3月24日

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  • Berkay Yuksel,
  • Pedram Samadian,
  • Matthew Hunt,
  • Ryan George,
  • Cameron Tolton,
  • Cyrus Yau,
  • Eric Boettcher,
  • Michael J. Worswick,
  • Cliff Butcher

摘要

The hot stamping of high strength 7xxx-series aluminum sheet provides near net-shape automotive components but requires specialized aging treatments to reach the target properties. Conventional approaches to determine the process window for solutionization heat treatments (SHT) of 7xxx-series aluminum seldom account for the forming strain, assume idealized processes that are not industrially-representative, and focus upon the strength response while overlooking the key role of bendability on crash performance. The current study develops a robust procedure to identify the hot forming process window for 7xxx series aluminum sheet with application to the recently commercialized automotive grade C7M7 alloy. The industrial hot stamping process was simulated in an automated test cell using solutionization temperatures of 473˚C and 495˚C for 3-to-15 min using a fast-heating contact furnace. The influence of the non-isothermal forming strain was considered using flat blanks and interrupted plane strain Marciniak tests. The microstructural evolution during the aging and paint bake treatments was characterized using electrical conductivity and hardness tests. The post paint-baking properties were characterized using miniature tensile and VDA238-100 tight-radius bend tests. Relatively short SHT durations of 3-to-5 min at both temperatures were found to produce similar properties. Accelerated aging kinetics and reduced peak hardness were observed as forming strain increased. For a forming strain of 25%, the UTS decreased approximately 5%, the total elongation decreased by 40%, and the plane strain bendability decreased by 25% compared to the blanks without forming strain. Property correlations were then developed to estimate tensile and fracture response. Demonstrator hat-channel rail parts were hot-stamped and the properties measured along different locations. Overall, the study elucidates the combined effects of hot forming and SHT parameters on the post-aging mechanical properties of hot stamped AA7xxx alloys, providing critical insight for component design and industrial production.