A high throughput in-situ measurement of heat transfer in successive non-isothermal forming of sheet alloys

The measurement and control of the heat transfer of sheet alloys in successive non-isothermal forming cycles is crucial to achieve the desired post-form properties and microstructure, which could not as of yet be realized by using traditional test facilities. In the present research, a novel heat transfer measurement facility was designed to generate and subsequently measure the in-situ heat transfer from a sheet alloy to multi-mediums such as forming tools, air, lubricant and coating. More importantly, the facility was able to use a single sheet alloy sample to perform successive non-isothermal forming cycles, and subsequently obtain high throughput experimental results including the temperature evolution, cooling rate, mechanical properties and microstructures of the alloy. The high throughput in-situ heat transfer measurement facility identified that the cooling rate of AA7075 was 152 °C/s and the mechanical strength was over 530 MPa in the 1st forming cycle. However, it decreased to less than the critical value of 100 °C/s in the successive 10th forming cycle, leading to a low mechanical strength of only 487 MPa. The identified variations that occur in the successive non-isothermal forming cycles would improve the consistency and accuracy of part performance in large-scale manufacturing.