Heat-assisted single point incremental forming of Mg-Zn-Zr alloy

Abstract

Abstract. Magnesium-zinc-zirconium (Mg-Zn-Zr) alloys, with their biocompatibility and biodegradability, exhibit great potential for biomedical applications. However, forming complex geometries poses a challenge due to the low formability of magnesium. Single Point Incremental Forming (SPIF) has emerged as a promising rapid manufacturing technique capable of producing complex-shaped, high-quality products. This preliminary study aims to investigate the feasibility of heat-assisted SPIF for Mg-Zn-Zr alloys, addressing formability at elevated temperatures, and the outcomes in terms of geometrical accuracy and material properties. Systematic parameter variations revealed that elevated temperatures and multistage toolpath strategies significantly improved formability, surpassing a 60° maximum wall angle. Nevertheless, this enhancement led to increased surface defects and reduced strength during forming at elevated temperatures. The key finding highlights the need for a balanced combination of elevated temperature and maximum wall angle to optimize surface quality and strength in complex geometries.