Functionally Graded AA7075 Components Produced via Hot Stamping: A Novel Process Design Inspired from Analysis of Microstructure and Mechanical Properties

Herein, functionally graded AA7075 components manufactured via hot stamping are investigated by focusing on the effect of different process variables on localized microstructure evolution. To realize gradation through stamping, an active tool is designed and applied. The design of experiments allows to assess the impact of transfer time from the furnace to the tool, quenching time in the tool, and final quenching media. Related characteristics of mechanical properties throughout the hat‐shaped profile are assessed via hardness and tensile tests. As expected, the sections of the samples formed in the cooled part of the tool are characterized by higher mechanical strength following subsequent aging, while sections formed in the heated part exhibit higher ductility. Moreover, the microstructural analysis reveals that fine precipitates with minimum interparticle distances only form in the cooled section of the samples. Increasing the tool temperature at the heated side to 350 °C results in the formation of coarse precipitates in the grain interior and along the grain boundaries. A sharp gradient in terms of microstructural and mechanical properties is found between these conditions. After reducing the transfer time, an increased volume fraction of fine precipitates leads to further improvements in hardness and mechanical strengths.