AA6082 alloys play a significant role in advancing sustainable development goals (SDGs) by contributing to environmental sustainability, economic growth, and social well-being. These alloys are highly recyclable and align with SDG 12 by promoting resource efficiency and reducing waste. Their application in lightweight vehicles and improving energy efficiency in construction supports SDG 9 and SDG 11, as they help reduce carbon emissions and enhance the sustainability of urban environments. While AA6082 alloys offer significant advantages, their use has limitations that can hinder their industrial applications. One key challenge is their lower formability, particularly at room temperature. Elevated-temperature deformation is frequently employed to enhance the formability of these alloys and address their limitations. Thus, a deep understanding of the constitutive analysis of these alloys under a wide range of $T$ and $\dot{\epsilon }$ is essential for manufacturing sound components from these alloys. Thus, this study aims to propose a new modification for the JC model (PJCM) and compare its reliability to predict the warm/hot flow behavior of AA6082 alloys with that of the original JC model (OJCM) and the modified JC model (LMJCM). By comparing the experimental results with these model results and confirming the determining correlation coefficient (R), average absolute relative error (AARE), and root mean square error (RMSE) values, it is concluded that the stresses predicted by the PMJCM closely match the experimental stresses of the LMJCM and OJCM because of the interaction between $\dot{\epsilon }$, $\epsilon$, and $T$, which might be a reason for the complex nonlinear behavior of AA6082 alloys during hot deformation.

This study aims to investigate the feasibility of hydroforming (HF) technology coupled with response surface optimization for producing high-quality five-branched AISI 304 stainless steel tubes with different diameters, addressing the shortcomings of traditional manufacturing processes. Conventional techniques often result in issues with multiple consumables, low precision, and subpar performance. The research focuses on finding optimal forming parameters for a more effective process. Initial attempts at a five-branched tube proved unfeasible. Instead, a multi-step forming approach was adopted, starting with the formation of the upper branch tube followed by the two reducing lower branch tubes, a strategy termed “first three, then five”. This method, enhanced by a subsequent solid solution treatment, yielded promising results: the combined height of the upper and lower branches was 141.1 mm, with a maximum thinning rate of 26.67%, reduced to 25.33% after trimming. These outcomes met the product usage requirements. Additionally, the study involved designing and developing dies for manufacturing five-branched tubes with different diameters using servo HF equipment. The effectiveness of the multi-step forming process and parameter combinations was confirmed through experimental validation, aligning closely with the FE simulation results. The maximum thinning rate observed in the experiments was 27.60%, indicating that FE simulation and response surface methodology can effectively guide the production of high-quality parts with superior performance.