Finite Element Simulation and Process Analysis for Hot-Forming WE43 Magnesium Alloy Fasteners: Comparison of Crystal Plasticity with Traditional Method

The WE43 magnesium alloy has gained attention in orthopedic implants due to its biodegradable properties, particularly for fabricating degradable fasteners. However, research on its hot-forming processes remains limited, primarily focusing on macroscopic finite element mechanical analyses. This study introduces a simplified high-temperature upsetting process and employs a mesoscale crystal plasticity finite element method to model the thermoforming behavior of WE43 fasteners for the first time. Comparative analyses with conventional finite element methods reveal that the crystal plasticity finite element method effectively captures the influence of microstructural evolution on macroscopic deformation. Additionally, temperature effects (25–650 °C) on mechanical performance were systematically evaluated. The results demonstrate that temperatures between 350 °C and 450 °C optimize formability, balancing thermal softening and strain hardening. The crystal plasticity finite element method framework provides enhanced predictive accuracy for micro–macro interactions, offering critical insights for designing biodegradable magnesium alloy implants.