The influence of pre-strain levels on the microstructure and performance of aircraft 7b04 aluminum alloy skin

Abstract

Abstract The study focuses on the 7B04 alloy sheet. It investigates the effects of different pre-strain levels on the microstructure, mechanical properties, and fatigue behavior of the alloy through the use of optical microscopy, scanning electron microscopy, and DIC (Digital Image Correlation) system. The experimental results demonstrate that the yield strength and tensile strength of the alloy increase with the increase in pre-strain levels. At the same time, the elongation decreases with the increase in tensile deformation. In the non-uniform region, the plastic deformation capacity index of the material (denoted as ψ) follows the order ψ (non-uniform region (DIC value)) > ψ (original gauge length value) > ψ (uniform region (DIC value)). It is recommended to control the maximum local strain below ψ (uniform region (DIC value)) during production to avoid deformation instability or concentration. Furthermore, the thickness of the material decreases linearly with increasing tensile deformation, with each 4% increase in tensile deformation resulting in a 1.2% reduction in thickness. The fatigue life of the alloy increases gradually with the increase in pre-strain levels in the direction perpendicular to the fiber. At the same time, it decreases in the direction parallel to the fiber. Different deformation levels and loading directions exhibit similar fatigue fracture characteristics. Within the range of 12% pre-strain levels, the microstructure of the material remains continuous and intact without noticeable cracks at grain boundaries or phase boundaries. At the macroscopic level, when the pre-strain level exceeds 6%, distinct slip bands appear on the sheet, which is correlated with the micro-scale grain slip. This is accompanied by deformation bands and micro-cracks in the microstructure. The findings of this study are of significant importance for understanding the influence of pre-strain levels on the mechanical properties and fatigue behavior of the 7B04 alloy. The study provides valuable references for engineering practices in related fields, thereby ensuring the integrity and usability of manufactured components.