Characterisation and modelling of multiaxial material behaviour for the design of a calibre rolling technology for hexagonal materials using the example of the magnesium alloy ZAX210

• Applicant: Dr.-Ing. Madlen Ullmann
• Subject Area: Primary Shaping and Reshaping Technology, Additive Manufacturing
• Term: since 2025
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 568606849

The aim of the proposed research project is to develop the material and process technology fundamentals for the development of a technology for the production of wire products made of hexagonal materials, using the example of a magnesium alloy by means of caliber rolling. To this end, there is a need for research to understand the forming behavior under complex, multiaxial loading. From the single- and multiaxial forming behavior, existing model approaches are to be used or extended, which describe the material flow and forming behavior as a function of temperature, forming speed and stress state. Finally, a test and validation is to be carried out. For the first project phase applied for here, the focus is to be on the understanding of materials and mechanisms during forming, for which laboratory tests and single pass rolling (single pass rolling process) will be used. On the one hand, the scientific questions regarding the mechanisms involved are to be clarified (mechanistic understanding) and, on the other hand, insights into targeted technology and microstructure/property modification (process-oriented understanding) are to be generated on the basis of the in-depth fundamental knowledge acquired. In the context of the project applied for here, all investigations are carried out on the basis of the Mg alloy ZAX210. Compared to AZ31, this alloy showed better forming properties during strip production, which should now also be made usable for wire production. In the second project phase, the transfer of knowledge to other magnesium alloys and other hexagonal materials (titanium and zirconium alloys) is planned. The models for material flow and forming behavior evaluated in the first model phase will be adapted for further material systems. Furthermore, a more in-depth technology analysis of material-oriented caliber rolling in several rolling passes is to be carried out. In doing so, the models created will be extended with regard to further variables (e.g. static/metadynamic softening mechanisms for further rolling passes and heat treatments) and evaluated for various process-technological variables (height reduction, roll gap, caliber selection and design, ...). The aim of the follow-up application is to close the scientific-technological knowledge chain for caliber rolling of hexagonal materials using the magnesium alloy ZAX210 as an example and to demonstrate the transferability of the findings to other hexagonal materials.

• DFG Programme: Research Grants
• Co-Investigator: Professor Dr.-Ing. Ulrich Prahl