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<p>Aluminium alloys exhibit favourable electrical and mechanical properties similar to brass, making them suitable for micro-electromechanical systems (MEMS) fabrication. In micro-scale forming, the thickness of sheets and microstructural characteristics strongly influence the plastic deformation and mechanical behaviour. In this study, AA1050 sheets with thicknesses of 30, 50, and 90&#xa0;µm were investigated through tensile and limit dome height (LDH) tests to evaluate forming limit strains. The as-received material showed very poor elongation due to very fine grains; therefore, annealing was performed to modify the microstructure and enhance ductility. With annealing, elongation increases while strength decreases. Microstructural evolution and texture changes were characterized using EBSD. Results show that formability decreases with miniaturization at a given grain size. Higher thickness specimens exhibited greater misorientation development and stronger texture evolution, leading to improved formability. The 50&#xa0;µm sheet experienced secondary recrystallization due to a larger grain size, while the 90&#xa0;µm sheet shows mixed textures that significantly enhanced formability compared with thinner sheets.</p>

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Microstructure, Texture, and Size Effects on the Tensile and Forming Behaviour of µ-Scale Aluminium Sheets

  • 期刊论文

  • 发表日期：

    2026年6月1日

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  • Jambeswar Sahu,
  • Sushil Mishra,
  • Shanta Chakrabarty,
  • Rajesh Raghavan

摘要

Aluminium alloys exhibit favourable electrical and mechanical properties similar to brass, making them suitable for micro-electromechanical systems (MEMS) fabrication. In micro-scale forming, the thickness of sheets and microstructural characteristics strongly influence the plastic deformation and mechanical behaviour. In this study, AA1050 sheets with thicknesses of 30, 50, and 90 µm were investigated through tensile and limit dome height (LDH) tests to evaluate forming limit strains. The as-received material showed very poor elongation due to very fine grains; therefore, annealing was performed to modify the microstructure and enhance ductility. With annealing, elongation increases while strength decreases. Microstructural evolution and texture changes were characterized using EBSD. Results show that formability decreases with miniaturization at a given grain size. Higher thickness specimens exhibited greater misorientation development and stronger texture evolution, leading to improved formability. The 50 µm sheet experienced secondary recrystallization due to a larger grain size, while the 90 µm sheet shows mixed textures that significantly enhanced formability compared with thinner sheets.