A theoretical and experimental evaluation of repetitive corrugation and straightening: Application to Al–Cu and Al–Cu–Sc alloys

Two alloys of Al–Cu and Al–Cu–Sc were processed for up to 4 passes using a facility for continuous repetitive corrugation and straightening (RCS). Hardness measurements were taken on the processed samples and specimens were cut from the processed sheets and tested in tension at room temperature. The results demonstrate that processing by RCS gives a very significant increase in hardness and this high level of hardness is introduced throughout the length of each sample. Thus, there is no wastage when metals are processed by RCS. The hardness values are further increased, and the degree of homogeneity is improved, if the samples are rotated by 90° between each consecutive pass through the RCS facility. The strength is higher for the Al–Cu–Sc alloy than for the Al–Cu alloy. A theoretical model is developed to explain the strength developed during processing by RCS. It is shown by calculation that the theoretical model is in excellent agreement with the experimental results.

► A facility was constructed for continuous repetitive corrugation and straightening. ► Tests with two aluminum alloys show that RCS introduces significant hardness. ► The hardness is high and homogeneous over the total length of each sample. ► The hardness is increased if samples are rotated by 90° between each pass. ► A theoretical model shows good agreement with the experiments.