Hydroforming of AZ61A tubular component with various cross sections

The effects of temperature on the mechanical properties and elongation of AZ61A tubular part were derived by uni-axial tension tests at various temperatures. Warm hydroforming of an AZ61A tubular part for passenger car was then numerically and experimentally investigated. The complete processes including bending, pre-forming and hydroforming were analyzed and discussed. Microstructure at the corner of the typical section was observed before and after the final hydroforming process. It is shown that the yielding strength, tensile strength and total elongation increase as temperature increases, while the elongation before necking decreases. The temperature range from 225 °C to 250 °C is more suitable for hydroforming of the AZ61A magnesium alloy tube with various cross sections. Pre-forming and hydroforming with high strain values are feasible at elevated temperature. Grain refinement is observed at the corner of the part after warm hydroforming. Thinning ratio analysis illustrates that non-uniform deformation at elevated temperature should be considered in process optimization to avoid severe local thinning.