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NTRODUCTION

IN today’s industrialized countries, the automobile plays an essential role not only for transportation, but also as a status symbol and as demonstration of prosperity. Consequentially, today’s high standard of living has a fundamental impact on the design and development strategy of automobile manufacturers. The refinement of structural designs, which include the specification of various light-weight material combinations, is essential for reducing the weight of a vehicle. Although specifying aluminum alloys in a design currently presents an expensive choice, when

R. SCHNEIDER is with Department of Mechanical and Marine Engineering, Western Norway University of Applied Sciences, 5020 Bergen, Norway and also with the Department of Mechatronics and Medical Engineering, Ulm University of Applied Sciences, 89081 Ulm, Germany. Contact e-mail: [email protected] R. J. GRANT is with the Department of Mechanical and Marine Engineering, Western Norway University of Applied Sciences. J. M. SCHLOSSER and W. RIMKUS are with the Lightweight Construction Centre, Aalen University, 73430 Aalen, Germany. K. RADLMAYR is with the voestalpine Metal Forming GmbH, 4020 Linz, Austria. F. GRABNER is with the Leichtmetallkompetenzzentrum Ranshofen GmbH, Austrian Institute of Technology, 5282 Ranshofen, Austria. CH. MAIER is with the Graduate School Ostwuˆ¥rttemberg GmbH, 73430 Aalen, Germany. Manuscript submitted April 30, 2019.

METALLURGICAL AND MATERIALS TRANSACTIONS A

considering the product life cycle savings potential (compared with those for materials currently used such as steels), the metal offers interesting possibilities. White[1] demonstrated that a body in white can be 40 pct lighter if made out of aluminum instead of conventional steels at reasonable costs. Miller et al.[2] comment that in addition to aluminum alloys demonstrating the ability to resist corrosion in various environments through the phenomena of passivation, other significant advantages are high rigidity (Young’s modulus/density), high specific strengths (strength/density), and good recyclability, which also favors this material for use in light-weight concepts. However, a disadvantage with high-strength aluminum alloys compared with modern steels is that the formability is low. Over the last few years, various approaches have been made with a view to improving the formability of numerous types of aluminum alloy sheet metal. With such strategies, a move towards elevating the temperature of the material is evident, including forming technologies that use temperature assistance. Forming procedures at raised temperatures allows parts with a greater degree of complexity to be produced. Schlosser et al.[3] presented the warm forming technique (forming temperature approx. 250 C) which allows the forming of ultrahigh-strength aluminum alloys in a fully hardened condition (T6) at an industrial scale. They demonstrated the first series produced car body crash

component made from AA7075-T6. However, due to its moderate forming enhancement, the warm formin