Sustainable manufacturing of ultra-fine aluminium alloy 6101 wires using controlled high levels of mechanical strain and finite element modeling

Abstract The evolution of grain size and component mechanical behaviour are fundamental aspects to analyse control when manufacturing processes considered. In this context, severe plastic deformation (SPD) processes, in which a high shear strain is imposed on the material, recognized as main techniques achieve microstructural changes material strengthening by recrystallization, attracting both academic industrial investigation activities. At same time, nowadays, sustainable design one responsibilities researchers looking at UN2030 agenda modern paradigms. paper new SPD process proposed with aim steer fourth revolution using some Industry 4.0 pillars. particular, additive (AM) numerical simulations were setup controlling monitoring wires. Strengthening effect (yield ultimate tensile strength, plasticity hardness) (continuous dynamic recrystallization -CDRX-) due experimentally analysed numerically investigated an innovative finite element (FE) model able validate effectiveness properly modified for ultra-fine aluminium alloy AA6101 wires production designed avoid any post costly thermal treatment. study provides accurate experimental prediction thermo-mechanical phenomena that occur during advanced large process; it shows how combination smart represents key renew traditional methods perspective 4.0, connecting integrating production.