**Abstract**

Industrial revolution toward weight reduction and fuel efficiency of the automotive and aerospace vehicles is the major concern to replace heavy metals with light weight metals without affecting much strength. For this, aluminum alloys are the major contributors to those industries. Moreover, aluminum alloys are majorly categorized as 1xxx, 2xxx, 3xxx, 4xxx, 5xxx, 6xxx, 7xxx, and 8xxx based on major alloying elements. Among all, 2xxx, 5xxx, 6xxx, and 7xxx are having majority of applications in the abovementioned industries. For manufacturing any engineering deformable components, forming characteristics are must. Forming behavior of aluminum alloys has been evaluated through different processes including deep drawing, stretching, incremental forming, bending, hydro forming etc., under different process conditions (cold, warm, and hot conditions) and process parameters. Each process has its own process feasibility to evaluate the formability without any forming defects in products. The present chapter discusses a few important processes and their parameter effect on the aluminum alloys through the experimentations and simulation works.

**Keywords:** ISF, hot forming, tube hydroforming, deep drawing, stretching

### **1. Introduction**

Formability is defined as plastic deformation ability to produce a part with definite requirements on mechanics, dimension, and appearance of a material during a forming process, being mainly limited by the occurrence of flow localization or variability. The formability of any sheet material depends on the material properties, process parameters, and strain bounding criteria. The formability can be evaluated through simulation tests like stretching, deep drawing and drawing processes, mechanical tests, limiting dome height (LDH), and forming limit diagrams at various conditions. Evaluating the formability of aluminum alloys is crucial for industries like aerospace and automotive due to their significant advantages over other materials. Aluminum alloys are majorly categorized as 1xxx, 2xxx, 3xxx, 4xxx, 5xxx, 6xxx, 7xxx, and 8xxx based on major alloying elements. Among all, 2xxx, 5xxx, 6xxx, and 7xxx are having majority of applications in any industry. Forming behavior of aluminum alloys has been evaluated through different processes including deep drawing, stretching, incremental forming, bending, hydroforming, etc., under different process conditions (cold, warm, and hot conditions) and process parameters. Each process has its own process feasibility to evaluate the formability without any forming defects in products. The significance of this chapter is to discuss and elaborate the effect of forming process parameters of different

**150**

*Aluminium Alloys and Composites*

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