The novel aluminum alloy AlMgSc (AA5028) shows a high potential for strongly loaded lightweight applications (e.g. airframe components) thanks to its relatively high strength properties and low density. Furthermore, the good weldability and high thermal stability of AlMgSc allows the use of innovative joining technologies (Friction Stir Welding - FSW as well as Laser Beam Welding - LBW) and advantageous forming methods (Creep Forming) for the fabrication of integral, large and thin-walled structures.
Hence, numerical and experimental investigations are carried out on the forming behavior of spherically curved and friction stir welded AlMgSc sheets. The focus of the studies is on the analysis of process parameters (forming pressure, forming temperature and time) to achieve optimum forming results (near net shape, low elastic springback, no cracking or wrinkling). Additionally, a flexible and simple tooling concept is developed to enable a low cost and energy efficient forming process.
The presentation will show the implementation and the results of both the numerical simulations and the forming operations. Also the potential of this innovative process variant with AlMgSc in comparison to conventionally used forming procedures with regard on aeronautical applications will be discussed.