Incremental forming and analysis of tailor welded aluminium alloy blanks and optimization of process parameters

Abstract

Aluminum and its alloys possess characteristics including light weight, high thermal, electrical conductivity and high specific strength. Much research works have been done and research works still going on Aluminum Tailor Welded Blanks (TWB) with similar thickness, different thickness and alloy combinations joint by various welding methods. TWBs are blanks that consist of two or more sheet pieces differing in materials, thickness, coating, and/or material properties that are welded together before forming into the required shape. Adjusting or tailoring the blank allows for the use of different materials and composites for various parts of the same component thereby reducing body-in-weight while providing extra reinforcements where it is locally required. Moreover, the structural integrity is maintained without changing the forming dies. The advantages of using TWBs are numerous, they ensure that the components are light, stronger, and provide required functionality at lower cost than parts made from monolithic pressed sheets, as well as improving structural integrity, safety and corrosion resistance in specific areas; and they allow greater flexibility in materials selection. The part integration possible with TWB reduces the number of parts and assembly time. However, the disadvantages of TWB are related to the heterogeneous nature of the blank (due to the weld and dissimilar materials used), where the thinner/weaker material may deform preferentially and tear prematurely in stamping, which also results in weld line movement and reduced formability due to weld. Hence it can be compensated by employing suitable welding and forming method. newline