Constitutive Analysis of the Deformation Behavior of Al-Mg-Si Alloy Under Various Forming Conditions Using Several Modeling Approaches

Bandar Alzahrani ¹

Ali Abd El Aty ¹

Yong Xu ^{2, 3}

Junying Min ⁴

Shi-Hong Zhang ^{2, 3}

Alamry Ali ¹

Mohamed M Z Ahmed ¹

Abdallah Shokry ⁵

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Department of Mechanical Engineering, College of Engineering at Al Kharj, Prince Sattam Bin Abdulaziz University, Al Kharj 11942, Saudi Arabia |

Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China |

Shenyang Key Laboratory for Aerospace Complex Components Precision Manufacturing, Shenyang 110016, China |

⁴

Institute of Forming Technology and Lightweight Components (IUL), TU Dortmund University, 44227 Dortmund, Germany |

⁵

Department of Mechanical Engineering, Faculty of Engineering, Fayoum University, Fayoum 63514, Egypt |

Publication type: Journal Article

Publication date: 2025-03-01

MDPI

Journal: Materials

scimago Q2

SJR: 0.565

CiteScore: 5.8

Impact factor: 3.1

ISSN: 19961944

DOI: 10.3390/ma18051121

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Abstract

The hot-flow behaviors of Al-Mg-Si alloy are complex because they depend on ε, ε˙, and T. Hence, it is vital to understand and determine the Al-Mg-Si alloy’s flow behaviors under several deformation conditions. Therefore, in this study, Crystal Plasticity (CP) modeling, modified Zerilli–Armstrong (MZA), and two JC models were developed to precisely determine the hot deformation behaviors of this alloy. The reliability and predictability of these models were evaluated via comparisons of the determined and experimental results acquired in the ε˙ range of 10−3 to 1 s−1 and T range of 400–550 °C. Additionally, statistical parameters including the RMSE, AARE, and R were utilized to assess these models’ reliability for determining this alloy’s flow behaviors under several forming conditions. By analyzing these statistical parameters and comparing the predicted and experimental stresses, it can be concluded that the flow stresses predicted by the CP modeling and S2-MJC model exhibit a strong alignment with the experimental flow stresses. This contrasts with the results from the MZA and S1-MJC models. These results are attributed to the ability of CP modeling to couple the microstructure state of this alloy and the interactions between ε and ε˙ on the one hand and between T, ε˙, and ε on the other hand, facilitated by a comprehensive set of parameters that link the dynamic recovery and softening mechanisms components in the S2‐MJC model.