The drive for carbon emission reduction has catalyzed a transformative shift in the automotive industry, with aluminum alloys becoming the preferred material solutions for manufacturing lightweighting vehicle structures. In particular, thin-walled aluminum extrusion sections are increasingly used in structural automotive components due to their high strength-to-weight ratio and design flexibility. This research investigates the global and local formability of aluminum alloys, which are vital for uniform deformation in early-stage forming and for damage resistance in late-stage forming. The discussion primarily focuses on thin-walled extruded profiles, which are commonly employed in lightweight automotive structures and are particularly sensitive to formability limitations during bending and shaping operations. By reviewing key aspects of the aluminum extrusion process—including casting, homogenization, extrusion, and aging—the study explores the influence of forming parameters and microstructural evolution on formability, supported by experimental and numerical analyses. Special attention is given to the role of crystal structures in enhancing local formability, as well as strategies for increasing recycled aluminum alloy content to meet sustainability goals. The study highlights current challenges, including improving dimensional accuracy, advancing characterization techniques, and integrating recycled materials into production. The findings underscore the importance of adopting innovative approaches such as in-situ monitoring, data-driven modeling, and adaptive process control to achieve intelligent and sustainable manufacturing. This paper offers a comprehensive perspective on the deformation mechanisms and control strategies for aluminum alloys, providing valuable insights for advancing lightweight, carbon-neutral automotive structures.
Moon et al. (Mon,) studied this question.