Comparative assessment of warm formability in Al–Mg alloys through limiting dome height experiments and finite element simulation studies

The increase in magnesium (Mg) content adversely affects the formability of Al–Mg alloys. Formability assessments for AA5052 and AA5083 alloys, featuring Mg content at 2.6 wt. % and 4.4 wt. %, respectively, were conducted through both experimental and finite element simulation methods at 25 °C, 200 °C, and 300 °C. The limit strains near plane strain conditions of the AA5052 alloy exhibited values of 12%, 12%, and 18% higher at 25 °C, 200 °C, and 300 °C, respectively, as compared to AA5083. Additionally, a positive sensitivity to formability with increasing test temperature was observed for both alloys. The variation of second-phase particles in both alloys was quantified using optical microscopy, revealing an increasing trend for both alloys with increasing temperature. Finite element simulations of the Limiting Dome Height (LDH) test were conducted to predict the formability of both alloys at various test temperatures. The formability predictions using the local thickness gradient-based necking criteria were better as compared to the maximum force necking criteria with relatively lower average absolute relative error (AARE) 60–75% lower for AA5052 alloy as compared to AA5083 alloy in the temperature range of 25–300 °C.