Gregor Michael AMAG

1. New high formable Al-Mg-Si product
for medium-strength applications
Automotive Lightweight Materials, 03/16/2023
Gregor Michael, M.Sc.

2. Agenda
1 Introduction
1.1 Processing and tempers of 6xxx aluminum grades
1.2 Dilemma between high formability vs. high paint bake response (PBR)
1.3 Product AMAG AL4® BIW 6ED-110
2 Comparison of mechanical properties for different products
3 Formability analysis
3.1 Erichsen cupping test
3.2 Automotive trial tool at Technical University of Graz
4 Conclusion

3. 1 Introduction

4. 4
1.1 Processing and tempers of 6xxx aluminum grades
 Temper of main alloying elements silicon and magnesium in the
microstructure is the essential factor that determines the material properties
 αsupersaturated  multiple Cluster formation steps  β (Mg2Si)
 Delivery condition in soft and good formable temper T4 by solving the alloy
elements
 Final curing with heat input during the paint bake process after forming
simulated over the temper T6
 Challenge of natural aging
Heat treatable material with main alloying elements silicon and
magnesium

5. 5
1.1 Processing and tempers of 6xxx aluminum grades
Different material tempers ideal for the production chain in automotive
industry
Fig. 1: Time-temperature course of aluminum processing within the
automotive industry

6. 6
1.2 Dilemma high formability vs. high paint bake response
High T6 material strength
 High strength in T4 ↑
 Alloy element content ↑
 Scrap content ↑
 Natural aging ↑
Main customer goals but contrasting material properties
High T4 cold formability
 Material strength ↓
 Alloy element content ↓
 Scrap content ↓
 Natural aging ↓

7. 7
1.3 Product AMAG AL4® BIW 6ED-110
 Chemical composition based on common EN AW-6016
 Higher iron content as basic requirement for increasing the scrap rate and
reducing the CO2 footprint
 xx
 xx
 Yield strength in temper T4 at approx. 110 MPa
New product development with high formability (ED-Electric Drive)

8. 2 Mechanical properties

9. 9
2 Mechanical properties
AMAG AL4® ABS 6OUT-110
 Standard outer skin alloy with yield strength of 110 MPa in T4 temper
 OUT – Outer skin
 OEM Specs:
AMAG AL4® BIW 6IBR-125
 Standard structural alloy with yield strength of 125 MPa in T4 temper
 IBR – Improved bake hardening response
 OEM Specs: /RE
Comparison with market-proven 6016 products

10. 10
2 Mechanical properties
Comparison with market-proven 6016 products in T4

11. 11
2 Mechanical properties
Comparison with market-proven 6016 products in T6

12. 12
2 Mechanical properties
 Strength level of the new product in temper T4 at the same level of
the outer skin alloy
 High work hardening exponent (n-value) implies that good formability can
be expected
 Excellent yield strength PBR of 130 MPa compared to 108 MPa (6OUT)
and 122 MPa (6IBR)
 Further studies show moderate natural aging behavior
 xxx
Comparison with market-proven 6016 products

13. 3 Formability analysis

14. 14
3.1 Erichsen cupping test
Stretch forming ability according to EN ISO 20482
Fig. 2: Schematic representation of the cupping test
according to Erichsen [1]

15. 15
3.1 Erichsen cupping test
Stretch forming ability according to EN ISO 20482
Fig. 3: Cracked cupping sample
after test run
Fig. 4: Evaluation of stretchability

16. 16
3.2 Automotive trial tool at Technical University of Graz
AMAG owned tool based on OEM needs
Fig. 5: Tool at TU Graz Fig. 6: Formed trial part to evaluate formability

17. 17
3.2 Automotive trial tool at Technical University of Graz
Forming limits
Fig. 7: Part with necking Fig. 8: Cracked part

18. 18
3.2 Automotive trial tool at Technical University of Graz
 Increase in formability by 50 % under production-related test conditions
Evaluation of forming result

19. 4 Conclusion

20. 20
4 Conclusion
 New product shows the high formability of an outer skin alloy combined with
the good hardening properties of a structural alloy
 Compared to the standard alloy, the scrap usage quota was increased by
40 % and the CO2-footprint was reduced by 30 %
 Excellent mechanical properties paired with the sustainability of the alloy
result in a wide and complex range of applications, especially in
electromobility
 High PBR offers scope for energy savings in the painting process
 Example applications: Battery platter, door inner & water catch strips
Perfect All-rounder

21. 21
Back-up
Phase diagram 6xxx Aluminum
Fig. 9: Al-Mg2Si quasi-binary phase diagram [2]

22. 22
Sources
[1] Banabic D, Bunge HJ, Pohlandt K, & Tekkaya AE, “Main tests used to
determine the FLD,” Formability of Metallic Material: Plastic anisotropy,
Formability Testing, Forming Limits, Springer, (2000).
https://doi.org/10.1007/978-3-662-04013-3.
[2] C. Kammer, “Aluminium Handbook Vol1: Fundamentals and
Materials”, Aluminium Verlag Marketing&Kommunikation GmbH, p.99,
(1999).
Figures

23. Thank you very much for your attention!