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<p>Incremental sheet forming (ISF) offers flexibility, high formability, and cost-effectiveness, making it highly suitable for small-scale production and complex aerospace components. This study investigates the formability and post-forming performance of cold-rolled partially cut-out blanks of AA7075-T6 sheets during the preparation of ISF parts. The process parameters under the statistical study include annealing condition, tool shape, and step depth, while formability was evaluated. The results revealed that annealing condition is the most dominant factor, followed by tool geometry and its interaction with annealing condition. The optimum combination of annealing at 238&#xa0;°C with a hemispherical tool produced a maximum forming angle of 70.95 degrees at a forming depth of 20.88&#xa0;mm. Annealing condition significantly reduced strength; however, due to localized work hardening in the formed region, microhardness increased. Potentiodynamic polarization studies revealed that the samples of the formed region with annealing condition AS238 exhibited improved corrosion resistance, aided by hemispherical tooling and smaller step depths. The EBSD analysis revealed that annealing condition AS238 showed enhanced texture intensity. Subsequent forming caused strain-induced recrystallization that slightly reduced texture intensity highlighting the combined effect of heat treatment and deformation on grain orientation.</p> Graphical Abstract <p></p>

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Formability Enhancement and Post-forming Characterization of AA7075-T6 Material in SPIF Process

  • 期刊论文

  • 发表日期：

    2025年12月2日

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  • Sudarshan Choudhary,
  • Amrut Mulay,
  • Parnika Shrivastava

摘要

Incremental sheet forming (ISF) offers flexibility, high formability, and cost-effectiveness, making it highly suitable for small-scale production and complex aerospace components. This study investigates the formability and post-forming performance of cold-rolled partially cut-out blanks of AA7075-T6 sheets during the preparation of ISF parts. The process parameters under the statistical study include annealing condition, tool shape, and step depth, while formability was evaluated. The results revealed that annealing condition is the most dominant factor, followed by tool geometry and its interaction with annealing condition. The optimum combination of annealing at 238 °C with a hemispherical tool produced a maximum forming angle of 70.95 degrees at a forming depth of 20.88 mm. Annealing condition significantly reduced strength; however, due to localized work hardening in the formed region, microhardness increased. Potentiodynamic polarization studies revealed that the samples of the formed region with annealing condition AS238 exhibited improved corrosion resistance, aided by hemispherical tooling and smaller step depths. The EBSD analysis revealed that annealing condition AS238 showed enhanced texture intensity. Subsequent forming caused strain-induced recrystallization that slightly reduced texture intensity highlighting the combined effect of heat treatment and deformation on grain orientation.

Graphical Abstract