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Microstructural Study, Anisotropic Behavior, and Mechanical Properties of AA3104 Aluminum Sheets for Beverage Can Manufacturing in the Deep Drawing Process

Khezri, Iman | 2024

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  1. Type of Document: M.Sc. Thesis
  2. Language: Farsi
  3. Document No: 58121 (07)
  4. University: Sharif University of Technology
  5. Department: Materials Science and Engineering
  6. Advisor(s): Akbarzadeh, Abbas
  7. Abstract:
  8. Aluminum alloys, due to their high strength-to-weight ratio and excellent corrosion resistance, are considered as an alternative to steel sheets in various industries. The high demand for aluminum alloys in this competitive market forces aluminum sheet manufacturers to thoroughly analyze their production processes in terms of both cost and final material properties, aiming to improve quality and reduce production costs through innovation. One of the most important applications of aluminum alloys is in beverage can manufacturing, where aluminum alloy 3104 is commonly used. These cans are primarily produced using the deep drawing method. The microstructure and texture anisotropy play a key role in improving the quality of these sheets. In this project, considering the industrial need, an experimental design (DOE) was conducted to identify the optimal mechanical properties and texture for these sheets during the deep drawing process. The sheets examined in this study (including imported Chinese sheets and experimentally produced sheets in Iran) underwent the final cold rolling process and were ready for use in beverage can production lines. This project was specifically designed to investigate the potential causes of earing defects in aluminum sheets and to compare the mechanical properties of domestically produced sheets with imported ones. The study included mechanical tests such as: Erichsen test, Tensile test (anisotropy analysis), Microhardness test, XRD macrotexture analysis and Microstructural evaluations using optical and electron microscopy. Additionally, the forming limit diagrams (FLD) and deep drawing die tests were conducted to assess the formability of the sheets. The results indicate that the imported sample has a higher average R-value (R̅) and a lower ΔR compared to other samples, which suggests lower anisotropy and better overall properties in the imported sheet. Furthermore, elemental analysis of the precipitates in the samples revealed that in addition to Al₆(Fe,Mn) (which is also present in domestically produced samples), the imported sample contains an additional Alₓ(Fe,Mn)ᵧSi precipitate. With an increase in the number of cold rolling passes, the intermetallic compounds β-Al₆(Fe,Mn) and α-Alₓ(Fe,Mn)ᵧSi become more fragmented and more uniformly distributed within the aluminum matrix. This leads to improved adhesion resistance during the deep drawing process. Additionally, the α-Al₁₂(Fe,Mn)₃Si phase, due to its higher hardness compared to the β-Al₆(Fe,Mn) phase, enhances wear resistance, improves die durability, and optimizes beverage can production. Further analysis among the domestically produced samples indicates that sample B exhibits better mechanical properties compared to the other two domestic samples. The crystallographic texture and ODF images at an angle of ϕ₂ = 45° reveal that the Copper texture component {112}<111>, which results from cold rolling, is stronger in the Iranian samples compared to the imported sample. Among the Iranian samples, sample B exhibits the lowest texture intensity, positioning it in a better condition than the other domestic samples
  9. Keywords:
  10. Deep Drawing ; Mechanical Properties ; Microstructure ; Forming Limit Diagram (FLD) ; Aluminum Beverage Can ; Aluminum Alloy 3104

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