Evaluation of hole expansion formability of high strength AA7075 alloy under varying temper conditions

There has been a widespread increase in the use of aluminum alloys in automotive industries for meeting ever-growing light-weighting requirements. However, edge formability is a critical manufacturing challenge that restricts their widespread use. Edge formability of sheet metal is determined using a hole expansion test (HET) and is evaluated by the hole expansion ratio (HER). The present study investigates the effect of temper conditions on the edge formability of AA7075 alloy sheets. Hole expansion tests were conducted in different temper such as W-temper (super saturated solid solution followed by water quenching), under aged (UA), and peak aged (PA) conditions. Two different hole preparation techniques, a punching and a drilling process, were used to prepare samples with varying edge conditions. The results demonstrate that the W-temper has the highest edge formability irrespective of hole edge conditions. Researchers have reported that uniaxial stress state prevails at the hole edge during the HET. Consequently, uniaxial tensile tests were conducted on for each temper condition and various tensile properties such as yield stress (YS), ultimate tensile strength (UTS), ratio of yield stress to ultimate tensile strength (YS/UTS) were determined to evaluate edge formability. Furthermore, microstructural and failure analysis of the failed specimens were performed to explain the deformation behavior during the HET.