Prediction of ductile fracture under non-isothermal conditions by a temperature-dependent Hosford-Coulomb model

Aluminum is becoming increasingly prevalent in automotive high voltage battery components, such as cell-cans, busbars and wiring. However, locally varying work-hardening states due to forming and changing temperature gradients during charging and discharging, pose challenges in predicting ductile failure due to temperature and recovery effects. To address this, the present study proposes a temperature-dependent extension of the Hosford-Coulomb model. The general capabilities of the model are demonstrated through a coupled thermo-mechanical finite element analysis, using the example of hot stamping of an AA5182-H19 sheet metal part. The obtained model predictions are then compared against experimental results, exhibiting a strong correlation across a range of temperatures. This approach enables the full exploitation of the potential of sheet metal components under non-isothermal operational loads, as well as for heat-assisted sheet metal forming processes.