Effects of Electrically Assisted Forming on the Microstructure and Mechanical Properties of 7050 Aluminum Alloy Thin-Walled High-Ribbed Forgings

  • XING, Zi-Han ,
  • HU, Jian-Liang
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    1. 1 College of Mechanical Engineering, Yanshan University, Qinhuangdao 066004, China
    2. 2 State Key Laboratory of Precision Manufacturing for Extreme Service Performance, Central South University, Changsha 410083, China
    3. 3 Deyang Wanhang Die Forging Co. Ltd., China National Erzhong Group, Deyang 618013, China

Received date: 2025-08-08

  Revised date: 2026-05-19

  Accepted date: 2026-05-28

  Online published: 2026-05-28

Supported by

National Natural Science Foundation of China(No. 52171018); Natural Science Foundation of Hebei Province(No. E2021203059); Central Guiding Local Science and Technology Development Fund Projects(No.236Z1016G); Open Research Fund of State Key Laboratory of Precision Manufacturing for Extreme Service Performance, Central South University(No. Kfkt2023-09); Open Research Fund of Sichuan Engineering Technology Research Center of Aviation Die Forgings.; Central Guiding Local Science and Technology Development Fund Projects(No.254Z4503G)

Abstract

7050 aluminum alloy thin-walled high-ribbed die forgings are essential structural components in aerospace engineering, necessitating a lightweight design coupled with high mechanical performance. However, conventional hot die forging often results in a substantial microstructural gradient distribution, characterized by coarse surface grains and severe inhomogeneity between the surface and core of the forgings due to rapid surface cooling when the billet contacts the die. These defects significantly degrade the mechanical properties and reliability of the components. In addition, conventional process optimization methods cannot fundamentally resolve these issues, often necessitating the removal of unacceptable surface layers, which leads to considerable material waste. Pulsed current-based electrically assisted forming (EAF) has demonstrated unique advantages in regulating metal plastic deformation and microstructure via the skin, electrothermal, and electroplastic effects. However, its systematic application in complex thin-walled high-ribbed die forgings has not been documented. To address these challenges, this study incorporates pulsed current into the conventional hot die forging process, taking 7050 aluminum alloy H-shaped thin-walled high-ribbed die forgings as the research object. Key parameters include a pulse voltage of 400 V, pulse width of 50 μs, and energizing time of 60 s. Two current frequencies, 600 and 1000 Hz, are selected as experimental variables to assess the regulatory effects of EAF on the microstructure and mechanical properties. The study employs finite element simulations to analyze current density and temperature field distributions, alongside multiscale experimental characterizations such as OM, EBSD, SEM, TEM, and tensile testing. This comprehensive approach reveals the microstructural evolution and strengthening mechanisms under electro-thermal-mechanical multifield coupling. Results demonstrate that the 600-Hz medium-frequency EAF process yields the optimal comprehensive regulation effect. The pulsed current mitigates surface heat loss during die forging, facilitates sufficient dynamic recrystallization, and generates uniform equiaxed grains throughout the cross-section, thus eliminating microstructural inhomogeneity. Moreover, the electro-thermal-mechanical coupling effect enhances solute solid solubility and boosts the contribution of precipitation strengthening to yield strength, leading to simultaneous improvements in strength and ductility. The mechanical properties of the surface and core of the forgings are highly balanced, with yield strength, tensile strength, and elongation measuring 495 MPa, 511 MPa, and 13.6% for the surface, and 492 MPa, 507 MPa, and 13.5% for the core, respectively. By contrast, the 1000-Hz high-frequency current exacerbates the skin effect, causing excessive current concentration on the surface and insufficient energy penetration into the core, resulting in incomplete recrystallization and increased structural inhomogeneity. Consequently, the mechanical properties of the 1000-Hz-processed forgings are inferior and less uniform. This study elucidates the regulatory mechanism of current frequency on the microstructural homogeneity and mechanical properties of complex aluminum alloy die forgings under electro-thermal-mechanical multifield coupling. The findings provide a novel and efficient technical approach for integrated microstructure-performance control in high-strength aluminum alloy thin-walled high-ribbed components, offering considerable potential for reducing material waste and enhancing component reliability in aerospace manufacturing.

Cite this article

XING, Zi-Han , HU, Jian-Liang . Effects of Electrically Assisted Forming on the Microstructure and Mechanical Properties of 7050 Aluminum Alloy Thin-Walled High-Ribbed Forgings[J]. Acta Metall Sin, 0 : 0 . DOI: 10.11900/0412.1961.2025.00220

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