Numerical and experimental study of forming high-strength aluminum sheet AA7075-To containing insoluble precipitates using damage and formability limit approachs.

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Authors

1 Faculty of Materials and Manufacturing Processes - Malek Ashtar University of Technology, Tehran, Iran

2 Faculty of Materials and Manufacturing Processes - Malek Ashtar University of Technology - Tehran - Iran

3 School of Mechanical Engineering, Iran University of Sience and Technology, Tehran, Iran

10.22044/jsfm.2026.16670.4005

Abstract

Abstract

Aluminum alloy 7075 is considered the highest strength of 7000 series alloys and is widely used in the aerospace industry. In this study, the formability limit of 7075 aluminum sheets containing insoluble precipatetes with an annealed temper a thichckness of 2.5 mm was evaluted accurately and comprehensively.Various studies were conducted in terms of damage mechanics approaches, formability limit, and numerical analyses. From the aspect of damage mechanics, insoluble precipitates in the metallurgical sttructure of the studied sheets were examined by electron microscopy and chemeical phase determination using X-ray diffraction, and the presence of insoluble precipitatets was proven.In the approach of determining of formability limit, two experimental tests of uniaxial tension and biaxial tension of Nakazima were performed in the studied sheets, and finally, the experimental diagrams of true strain stress and formability limit diagrams were extracted. Due to the presence of insoluble precipitates and their inhomogenous distribution in the studied sheets, with an increases in the number of Nakazima test samples, the effects of defects on formability diagram became more pronounced.this diagram was used in such away that the effect of heterogenity was considerd with appropriate accuracy.In the numerical approach, the experimental test to determine the formability limit (Nakazima test)was simulated by two software programs: Abaqus v2021 and Autoform v11. The location of the crack and rupture was well matched with the experimental results in the numerical analtsis. Finally, showed that formability limit of the sheets was reduced by 25 percent due to the presence of insoluble precipitates.

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Journal of Solid and Fluid Mechanics

Articles in Press, Accepted Manuscript
Available Online from 06 June 2026

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