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Determination of forming limit diagrams (FLDs) by experimental methods requires a significant amount of time and expertise in interpretation of data. Their construction can be especially difficult for aluminum alloys due to slightly negative or near zero strain rate sensitivity characteristics which create sharp strain gradients. For this reason a mathematical model which incorporates microstructural attributes, namely crystallographic texture, with a description of strain hardening behavior was developed by Barlat1 to predict the forming limit strains for a given material. Using Barlat, forming limit diagrams were predicted for various automotive body sheet alloys and verified against experimental data. Excellent correlation was found between the experimental and predicted diagrams. Prediction of limit strains requires approximately one-tenth of the time required for experimental diagrams and eliminates variations associated with experimental determination techniques.

Draw bead simulator tests were performed on various tool materials using aluminum alloys 2008-T4 and 6111-T4. The tool materials included hardened cast steel J435/0050A, D2 alloy, cast steel with ion nitride and PVD chromium nitride surface treatments, and cast steel with standard chromium and Wearalloy™ chromium coatings. Friction and galling behavior were monitored over an extended period of testing which allowed differentiation of the tool materials and alloys. Wearalloy™ and CrN tool coatings consistently demonstrated improved ability to prevent material transfer for both aluminum alloys, in spite of friction coefficients which were higher than the uncoated and ion nitrided tools. The ion nitrided surface exhibited the lowest friction coefficients of the surface treatments tested, but showed appreciably more wear. For a given lubricant and dilution ratio, alloy 2008-T4 exhibited an increased tendency for material transfer compared to alloy 6111-T4 for all tool materials tested.

Classically, structural component fatigue design is based on testing and empirical models. First a series of average stress-life curves are generated from fatigue tests. Constant life diagrams are then developed accounting for mean stress effect, casting quality, surface finish, volume and other factors. Component design is then based on keeping the effective alternating stress below the diagram limit stress. While this procedure has worked well to design many components, it is based on extensive fatigue testing and empirical stress reduction factors. Thus, material and process improvements and computerization of the design process are difficult to incorporate into this test/empirical based design methodology. Fracture mechanics and damage tolerant design methodologies are used in aerospace for fatigue design. These methods predict well the fatigue life for surface scratches (rogue inspectable flaws) of about 0.25-1.27 mm in size.

Three metallurgical factors have a major influence on the machinability of aluminum castings: chemical composition, heat treatment, and foreign inclusions. Othermet-allurgical factors that may also affect machinability are generally related to one of these three items. In general, aluminum alloys have good machining characteristics, although tests indicate that they cover a range. Some of the differences that do exist are discussed and practices identified that lead to improved machinability.