Establishing Equal-Channel Angular Pressing (ECAP) for sheet metals by using backpressure: manufacturing of high-strength aluminum AA5083 sheets

Abstract Severe plastic deformation (SPD) processes offer the possibility of improving mechanical properties metallic materials by grain refinement. However, this great potential has so far mostly been applied on a laboratory scale or small series. Equal-Channel Angular Pressing (ECAP) also enables to integrate advantages in industrial with large output—so far, mainly for bars thick plates. In paper, we investigate ECAP process sheet metal. Preliminary investigations have shown that cracks form surface when aluminum AA5083 sheets are processed. To solve problem, determined Johnson–Cook fracture criterion material and modeled numerically. The simulation was carried out superposition backpressure subsequently implemented validated experimentally. semi-finished metal products from investigation were then mechanically characterized microhardness measurements tensile tests. addition, microstructure investigated Electron Back Scatter Diffraction (EBSD). Even comparatively amounts (10 MPa) already result significant suppression crack formation numerical experimental investigations. indicate more homogeneous strain distribution sufficient level which processing crack-free multiple passes. As bulk materials, tests processed show reduced elongation failure (− 73%) but significantly increased yield strength (+ 157%) compared initial condition material. Distinct substructures found EBSD explain behavior. findings provide basis using an application-oriented demonstrate advanced manufacturing method production high-strength sheets.