Breaking through the bending limit of Al-alloy tubes by cryogenic effect controlled mechanical properties and friction behaviours

Aluminium alloy (Al-alloy) tubes, especially large-diameter thin-walled tubes with a tough bending radius, have been widely utilised in different industrial clusters owing to their high strength-to-weight ratio and good corrosion resistance. However, achieving such extreme specifications is challenging because severe and nonuniform bending deformation may cause tension and compression instabilities, such as overthinning, cracking, and wrinkling. Considering possible improvements in mechanical properties and friction behaviours of Al-alloy at cryogenic temperature (CT), the cryogenic bending potential of the 6061-O tubes with an extreme ratio of D/t of 89 (diameter/wall thickness) was explored at different deformation temperatures, including room temperature (RT) 20 °C, −60 °C, −120 °C, and −180 °C. First, the cryogenic mechanical properties and friction behaviour of the tubes were characterised. It was found that the overall mechanical properties of the Al-alloy tube were improved because of sub-grain formation and a more uniform distribution of dislocations at CT. The coefficient of friction between the tube and tooling exhibited a varying degree of reduction owing to the sensitivity of the tubes and the lubricant to CT. Subsequently, an innovative experimental platform for cryogenic bending was designed, and a finite element model of cryogenic bending was established. Third, cryogenic tube bendability and mechanism were explored. It was found that 6061-O tube formability can be effectively improved by cryogenic bending; however, there is no monotonic relationship between the bendability improvement and temperature decrease. The temperature to obtain the best bendability is −60 °C, at which the average wrinkle height is decreased by 81.4 %, and the average wall thickness reduction rate is reduced by 23.8 %. The bending limit represented by the bending radius is reduced from a 3.0D bending radius at RT to 1.0D at −60 °C, which is realised by the different or even opposite effects of the mechanical properties of tubes and the friction coefficient between the multiple contact interfaces on wall thinning and wrinkling.