Electromagnetic forming (EMF) is a forming process that relies on the inductive electromagnetic force to deform metallic workpiece at high speed. Calculation of the electromagnetic force is essential to understand the EMF process. However, accurate calculation requires complex numerical solution, in which the coupling between the electromagnetic process and the deformation of workpiece needs be considered. In this paper, an appropriate formula has been developed to calculate the electromagnetic force in metal work-piece in the sheet EMF process. The effects of the geometric size of coil, the material properties, and the parameters of discharge circuit on electromagnetic force are taken into consideration. Through the formula, the electromagnetic force at different time and in different positions of the workpiece can be predicted. The calculated electromagnetic force and magnetic field are in good agreement with the numerical and experimental results. The accurate prediction of the electromagnetic force provides an insight into the physical process of the EMF and a powerful tool to design optimum EMF systems.

In this paper, infrared thermography was employed to study the fatigue process of AZ31B magnesium alloy. In order to eliminate the interference caused by the temperature rise of the fixture, a data processing method was proposed, which is based on a special model to describe the temperature change of the specimen. Based on the temperature data after processing, the temperature evolution indicates that AZ31B magnesium alloy has undergone cyclic hardening during fatigue. Three different temperature indicators were selected to evaluate the fatigue limit based on the evolution curve after processing. In addition, the experimental results showed that the temperature data processed by the proposed method can be used to estimate the fatigue limit of AZ31B magnesium alloy. Experiments were performed for both extrusion and transverse directions in consideration of the anisotropy of the AZ31B.

A new criterion for hydrogen-induced cracking (HIC) that includes both the embrittlement effect and the loading effect of hydrogen was obtained theoretically. The surface cohesive energy and plastic deformation energy are reduced by hydrogen atoms at the interface; thus, the fracture toughness is reduced according to fracture mechanics theory. Both the pressure effect and the embrittlement effect mitigate the critical condition required for crack instability extension. During the crack instability expansion, the hydrogen in the material can be divided into two categories: hydrogen atoms surrounding the crack and hydrogen molecules in the crack cavity. The loading effect of hydrogen was verified by experiments, and the characterization methods for the stress intensity factor under hydrogen pressure in a linear elastic model and an elastoplastic model were analyzed using the finite-element simulation method. The hydrogen pressure due to the aggregation of hydrogen molecules inside the crack cavity regularly contributed to the stress intensity factor. The embrittlement of hydrogen was verified by electrolytic charging hydrogen experiments. According to the change in the atomic distribution during crack propagation in a molecular dynamics simulation, the transition from ductile to brittle fracture and the reduction in the fracture toughness were due to the formation of crack tip dislocation regions suppressed by hydrogen. The HIC formation mechanism is both the driving force of crack propagation due to the hydrogen gas pressure and the resisting force reduced by hydrogen atoms.

In this paper, the fatigue limit of AZ31B magnesium alloy is evaluated according to the surface temperature of the specimen during the test. Considering the influence of external heating, a special data-processing method is used to filter the raw temperature data obtained by the infrared camera. A thermal indicator based on the analysis of superficial temperature distribution is described and proposed. In contrast, most existing thermal indicators are calculated based on temperature evolution. Three existing algorithms were used to evaluate the fatigue limit of AZ31B magnesium alloy based on the newly proposed thermal indicator. In addition, the results of the test were used to compare with the results of traditional methods. It has been proved that the fatigue limit of AZ31B magnesium alloy can be assessed by using the new thermal indicator based on temperature distribution.

An evaluation method is proposed for determining the full fatigue life of aluminum alloy cruciform joint, including the crack initiation and propagation with welding residual stress. The results of simulations have shown that the boundary between the initiation and propagation stage is not constant, but a variable value. The residual stress leads to a significant reduction in both stages, which is more severe on initiation. With considering residual stress, the ratio of crack initiation to total life is below 7%. The effect of residual stress varies with external loading; when external load is lower, the residual stress has a greater effect.

AZ31B magnesium alloy is the experimental material in this study. Considering its anisotropy, fatigue assessment based on self-heating is carried out for both the extrusion direction and the transverse direction. The self-heating behavior in the two orientations is compared. Similar to steels, an obvious inflection point that corresponds to the fatigue limit can be found in the self-heating vs. load curve for AZ31B. A new fatigue limit assessment method is proposed based on a statistical analysis of self-heating data. This method can provide a satisfactory assessment of the fatigue limit for AZ31B in the both orientations.