Formability of AA7021-T4 Sheet Alloy Under Changing Strain Path Conditions: Experiments and Crystal Plasticity Modeling

The formability of AA7021-T4 sheets under changing strain paths was investigated via a novel crystal plasticity model and associated experimentation. The motivation was to advance simulation tools for process design of limited-ductility 7xxx alloys, with important applications in the automotive industry. Pre-strains were applied in biaxial and plane-strain tension using Marciniak tooling, followed by uniaxial tensile testing to failure. Strain measurements were obtained by digital image correlation, while dislocation structures were characterized using high-resolution EBSD. A strain-gradient elasto-plastic self-consistent (SG-EPSC) model incorporating dislocation density-based hardening and backstress from geometrically necessary dislocations (GNDs) was employed to predict the stress–strain response and dislocation evolution. Results showed that pre-strains normalized by forming limit diagram (FLD) criteria produced comparable residual uniaxial tensile ductility, regardless of whether biaxial or plane-strain tension was applied, despite differences in absolute pre-strain levels. Both experiments and simulations revealed that GND density correlated with remaining ductility better than simple strain magnitude values. These findings indicate that AA7021-T4 retains greater formability under multiaxial strain path changes than expected from FLD-based considerations. The combined experimental–modeling approach demonstrates the value of incorporating microstructure-based variables, such as GNDs, into forming assessments of high-strength aluminum alloys, with implications for their potential use in automotive lightweighting development.