Research on the application of additively manufactured polymer (AMP) to the conventional manufacturing process is underway. In this study, an additively manufactured die-set (AMDS) was used and applied to the warm forming of the magnesium alloy. Heat transfer and coupled temperature-displacement analysis were conducted in the V-Bending and UBending processes to study the applicability of the AMDS to the warm-forming process of the magnesium alloy sheet (AZ31B). A heat transfer experiment was conducted to determine the thermal contact conductance between the AZ31B material and two types of die-set, the metal and AMP. V-Bending and U-Bending experiments were conducted at 373 and 423 K; reduction in temperature between metal die-set and the additively manufactured polymer die-set were compared. The springback after the bending process with different initial temperatures and die materials was investigated. The simulation model showed good agreement. The springback of AZ31B was more decreased with the additively manufactured polymer die-set than with the metal die-set. The stress of the additively manufactured polymer die-set in the bending process was very small. It was confirmed that in the AZ31B material, the additively manufactured polymer die set helps increase the formability and decrease springback by keeping the temperature of AZ31B better.

The purpose of this study was to investigate the springback behavior of magnesium alloy (AZ31B) at high temperature with respect to the holding time in the die-set. The changes of microstructure in the springback during V-Bending were analyzed. The springback of the magnesium alloy sheet showed a tendency to decrease as the forming temperature and the retention time in the die increase. In the microstructure analysis, there was minimal change in the microstructure at room temperature, while at high temperature the microstructure changed markedly. The increasing material holding time in die has been shown to reduce springback from internal energy reduction because of recrystallization and grain growth at high temperature.

A simple and rapid method of fabricating Mg(OH)2 layer by chemical immersion was developed to improve the corrosion resistance of the magnesium alloy AZ31. The fabricated surface was superhydrophobic with a self-assembled monolayer coating of silane. The surface characteristics were evaluated by Scanning Electron Microscopy (SEM), Energy Dispersive X-ray Spectroscopy (EDS) and X-ray Photoelectron Spectroscopy (XPS). The average water contact angle and sliding angle were determined to be 160° and 7° respectively as a result of wettability test. Potentiodynamic polarization indicated that both Mg(OH)2 layer and the thin layer of air were effective in improving anti-corrosion. This method which is efficient with regard to time and cost would be useful for magnesium industries and its application