Preliminary studies on the suitability of rheocast Al alloys for deep drawing

This work analyses comparatively the behaviour of AlMg 5052 alloy sheets, in rolled and rheocast conditions, in deep drawing operations. Tensile tests and Erichsen cupping tests were performed to evaluate deformation behaviour in the two types of structures. Results showed higher deformation at lower required forces for rheocast material. Tensile test showed %EL four times higher, YS three times smaller and UTS two times smaller in the rheocast sheets compared to the rolled condition. Erichsen tests showed failure of rheocast at Fmax 24% smaller and total displacement 38% higher than rolled sheets. Fracture analysis showed distinct patterns, coalescence of dimples leading to fracture in rolled material, intergranular crack in rheocast. To produce the same degree of deformation, rheocast material requires 50% of the force required for rolled sheet. General results shows therefore, in terms of processing, that rheocast material can be an interesting raw material for deep drawing operations, meaning significant energy savings and formability improvement.