Basic Study On Applying The Plastic Forming Of 4032 Al-alloy

Difficult-to-form Aluminum alloy has characteristics that general Aluminum alloyhas,such as low density, bright color, good corrosion resistance, easy to process, no lowtemperature brittleness, no magnetism, good thermal and electrical conductivity. Furthermore, it has a high specific strength and a high specific stiffness. All these advantagesmake the difficult-to-form Aluminum alloy widely used in aerospace area, nationaldefence area and car manufacture erea。In order to develop energy-saving, environment-protective product, a most difficultproblem that motor industries have to face with is how to light the weight of cars. The carweight and the energy comsumption can be effectly decreased by using difficult-to-formaluminum alloy parts. The 4032 aluminum alloy has a high silicon content as much as11%~13.5%, therefor, the 4032 has good abrasive resistance and a small coefficient ofthermal expansion, compared with other difficult-to-form aluminum alloys. All thesemake the 4032 aluminum alloy the ideal material of the key parts of noise-free carairconditioner compressor, such as piston rod and scroll.These middle and high silicon aluminum alloy parts used to be made by pressurecasting. But the air tightness is affected by casting flaws such as gas cavity and shrinkageporosity, and the mechanical properties are affected by the bulk primary silicon in the caststructure. So, it's hard to meet the requirments of modern car airconditioner compressor.The pressure casting flaws can be effectly avoided by applying hot precision die forgingprocess. So, the thesis focused on replacing casting process with die forging process , anddesigned a basic research on difficult-to-form aluminum alloy.By applying the Zeller-Hollomon constitutive model, a high temperature compressionexperiment has been designed to research the rheological behavior of 4032 aluminumalloy and to figure out its constitution equation. Secondly, a hot extrusion experiment hasbeen designed to research the hot deformation behaviour of 4032 aluminum alloy underthe same extrusion velocity and different temperature or different extrusion degree, and toresearch the extrusion's microstructure and mechanical properties. In the end of the experiment, it analyzed the influence of technological parameters, such as extrusiontemperature and deformation degree, to the microstructure and mechanical properties.Finally, the hot extrusion experiment under different temperature and deformation degreehas been simulated on the DEFORM platform, analyzing the rule of deformation and thedetail data of the material's flow field ,velocity field, stress and strain field , strain ratefield and temperature field, etc. It provided scientific references for choosing precision dieforging process and technological parameters of the 4032 Al-alloy.