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<p>This study presents a novel pre-hardened forming (PHF) process for 6082 aluminum alloy, which consists of pre-aging, preheating, and forging. Compared to traditional forging processes (preheating-forging-solution treatment-aging), this process enhances the mechanical properties of the alloy and eliminates all post-forging heat treatment steps. A systematic investigation was conducted on aging parameters (160-200&#xa0;°C/4-10 hours) and deformation temperatures (200-230&#xa0;°C). The results show that increasing the deformation temperature from 200 to 230&#xa0;°C decreases the forming stress in most cases. The optimal hardness (120 HV) was obtained via aging at 160&#xa0;°C for 4&#xa0;hours followed by soaking at 200&#xa0;°C for 10&#xa0;minutes. Electron backscatter diffraction (EBSD) and transmission electron microscopy (TEM) were used to characterize the microstructural evolution of deformed alloy samples with the highest and lowest hardness. The results show that the alloy sample with the highest hardness exhibited a significantly higher dislocation density and a denser distribution of <i>β</i>′′ phases compared to the lowest-hardness sample. This indicates that the new forging process, which eliminates post-forging solution treatment, can simultaneously improve the mechanical properties of forged components and enhance production efficiency compared to traditional forging processes. This breakthrough provides an innovative approach for manufacturing high-performance lightweight components in the automotive industry.</p>

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Study on the Microstructure and Mechanical Properties of 6082 Alloys for Pre-hardened Forging Process

  • 期刊论文

  • 发表日期：

    2025年11月6日

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  • Qian Sun,
  • Zehan Zhang,
  • Jia Zheng,
  • Yi Yang,
  • Zhili Hu

摘要

This study presents a novel pre-hardened forming (PHF) process for 6082 aluminum alloy, which consists of pre-aging, preheating, and forging. Compared to traditional forging processes (preheating-forging-solution treatment-aging), this process enhances the mechanical properties of the alloy and eliminates all post-forging heat treatment steps. A systematic investigation was conducted on aging parameters (160-200 °C/4-10 hours) and deformation temperatures (200-230 °C). The results show that increasing the deformation temperature from 200 to 230 °C decreases the forming stress in most cases. The optimal hardness (120 HV) was obtained via aging at 160 °C for 4 hours followed by soaking at 200 °C for 10 minutes. Electron backscatter diffraction (EBSD) and transmission electron microscopy (TEM) were used to characterize the microstructural evolution of deformed alloy samples with the highest and lowest hardness. The results show that the alloy sample with the highest hardness exhibited a significantly higher dislocation density and a denser distribution of β′′ phases compared to the lowest-hardness sample. This indicates that the new forging process, which eliminates post-forging solution treatment, can simultaneously improve the mechanical properties of forged components and enhance production efficiency compared to traditional forging processes. This breakthrough provides an innovative approach for manufacturing high-performance lightweight components in the automotive industry.