Investigation on the forming behaviour of metal/polymer laminates

A metal/polymer laminate is a new light weight sheet material suitable to replace conventional steel or aluminium sheet in future car designs. In this study the effect of material composition and process conditions on the forming behaviour of metal/polymer laminates in sheet metal forming was investigated by experimental, analytical and numerical methods.

Experimental analysis of friction in forming automotive coated steels

The thesis addressed and answered a number of key issues in the experimental analysis of friction in sheet forming operations. Conventional friction theories were linked with the properties of sheet coatings and the process geometries. Newly derived mathematical models extended the analysis of friction in sheet metal forming applications.

Springback behaviour of TRIP steels in sheet metal forming

Examines the methods for numerical modelling of the springback effect in TRansformation Induced Plasticity (TRIP) steels under conditions of various bending processes. It represents a largely unexplored part of the TRIP steel literature and therefore makes a valuable contribution toward a practical approach to predicting springback in TRIP steels.

Advanced modelling of forming high strength steels

The thesis presents a novel approach in the multiscale modelling of Advanced High Strength Steels for prediction of the microstructural effects in forming processes. The results are compared with that of experiments and finite element method. The method is proved to be suitable for complexities in the multiphase AHSS.

Robust surface practices for sheet metal forming dies

Examines the use of surface coatings in stamping using an overall systems approach. The effects of die coating surface properties on friction, wear and part strain, have been studied in-plant with an emphasis on optimising the tool coating system to provide robust sheet metal forming procedures.

Effects of aging bake hardenable steel in sheet metal forming

Bake hardening steels are being used as body panels in modern cars. These steels are stronger through an ageing process after baking in the paint ovens, which allows the thickness of the steel to be reduced without reducing the denting performance. The current study examined whether the steel ages at room temperature prior to forming which would deteriorate the formability. The work developed a new test and provided insight into acceptable levels of natural ageing which could be tolerated in the manufacturing process.

Evaluation of cold forming lubricants for fastener manufacturing

Investigates the significance and interactive effects of lubricant type, workpiece surface texture and deformation rate under bulk metal, deformation conditions. A novel test rig was developed in conjunction with statistical test techniques. The result of this work identified a cold forming lubrication system with potential economic and environmental advantages over traditional lubrication systems.

Press forming performance of galvanneal coated steel

This project quantified the press formability of galvanneal coated steel. A coil of galvanneal coated steel was produced containing various coating structures. Using different lubricants, the powdering, friction and forming properties were determined. It was found that optimum formability was obtained by effective lubrication while galvanneal coating structure controlled powdering resistance.

Mechanical properties and blow forming of rolled AZ31 Mg alloy sheet

Rolling was conducted at 373-673 K for AZ31 Mg alloy; mechanical properties of the rolled Mg alloy were investigated by tensile and blow forming tests. The grain sizes of all the rolled specimens were smaller than that of the specimen prior to rolling. At tensile temperatures under 373 K, the rolled specimens showed much higher 0.2% proof stresses than the non-rolled specimens due to their fine-grained microstructure. However, the strength of the rolled specimens decreased significantly at 473 K. Superplastic behavior was obtained at 573-723 K for the specimens rolled at 498 K. Blow forming tests demonstrated that specimens rolled at 498 K exhibited a high degree of formability at 723 K.

Effect of pore size on mechanical properties of titanium foams

In the study, both experimental work and numerical modeling are performed to investigate the pore size effects on the mechanical properties and deformation behaviours of titanium foams. Cylindrical titanium foam samples with different pore sizes are fabricated through powder metallurgy. Scanning electron microscope (SEM) is used to determine the pore size, pore distribution and the ratios of the length to width of pores. Compressive tests are carried out to determine the mechanical properties of the titanium foams with different pore sizes. Finally, finite element modeling is attempted to simulate the deformation behaviour and the mechanical properties of the titanium foams. Results indicate that titanium foams with different pore sizes have different geometrical characteristics, which lead to different deformation behaviours of cell walls during compression, resulting in different mechanical properties of titanium foams.

Theoretical study on behaviour of superplastic forming/diffusion bonding of bulk metallic glasses

Based on the behaviour of the superplastic deformation of metallic glasses and Pilling’s model, a diffusion bonding model suitable for metallic glasses is proposed in the present study. In the current model, the diffusion bonding processes consists of two stages: one is the plastic deformation stage and the other is the void shrinkage stage, in which, the atom diffusion and superplastic deformation are responsible for the void shrinkage. Applying this model to the diffusion bonding of a Zr based metallic glass, the predicted bonding time is in good agreement with the experimental result. A map for determining the bonding temperature and time to achieve high quality bonding in a Zr based metallic glass is suggested.

Restoration of the habitat-forming fucoid alga Hormosira banksii at effluent-affected sites : competitive exclusion by coralline turfs

Fucoid algae often dominate intertidal rocky shores, providing habitat and modifying ecosystem resources for other species, but are susceptible to discharge of sewage effluent. In this study we assessed the potential for competition from coralline turfs to inhibit restoration of the intertidal fucoid macroalga Hormosira banksii at sites associated with an ocean outfall a scenario of improving following water quality in the nearshore coastal environment. The percentage cover and number of individuals of H. banksii were negatively correlated with both the percentage cover and turf height of Corallina officinalis. In contrast, H. banksii was positively associated with rocky substrata and recruited well to rock-surface substrata. Importantly, there appears to be a threshold abundance where the percentage cover of H. banksii rarely reaches above 20% cover amongst coralline turfs with >40% cover. These data support a model of alternative community states: H. banksii dominated canopy on rocky substrata versus C. officinalis turf. In field and laboratory experiments, extensive coralline turfs (up to 4 cm thick) were shown to inhibit recruitment of H. banksii. This study shows competitive exclusion by coralline turfs may limit the successful restoration of habitat provided by H. banksii to shores that have been affected by sustained discharge of secondarily treated sewage effluent. We suggest potential strategies for management authorities to consider when seeking ways of restoring fucoid communities affected by anthropogenic disturbances such as wastewater disposal.