High Voltage, High Hopes: A Cautionary Tale of Through-Thickness Electroplastic for Springback Reduction

High Voltage, High Hopes: A Cautionary Tale of Through-Thickness Electroplastic for Springback Reduction | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article High Voltage, High Hopes: A Cautionary Tale of Through-Thickness Electroplastic for Springback Reduction Eneko Saenz de Argandoña, Manex Barrenetxea, Iosu Aizpuru, Javier Trinidad, and 2 more This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-7242556/v2 This work is licensed under a CC BY 4.0 License Status: Posted Version 2 posted You are reading this latest preprint version Show more versions Abstract This work explores the feasibility of inducing springback reduction in AA5754 aluminium alloy sheets using a novel approach: Post-Forming Through-Thickness Electroplastic Effect (PF-TT-EPE). The concept aims to deliver high-energy electrical pulses directly through the sheet thickness via embedded tooling electrodes, enabling stress relaxation without external fixtures or process interruption. While theoretically promising, the experimental campaign encountered critical implementation challenges. Despite establishing a repeatable baseline springback of 11.8 ± 0.5°, all attempts to apply pulse trains above ~ 600 A·ms/mm² resulted in uncontrolled spark discharge, severe sample damage, and tooling degradation, linked to air gap formation and dielectric breakdown at the interface. At lower energies, the process proved electrically safe but ineffective in reducing springback. These findings highlight the fragility of die-integrated electrical delivery systems and expose the hidden complexity of ensuring stable, conductive contact under forming conditions. Rather than demonstrating success, this study contributes a clear boundary to the applicability of electroplastic forming techniques and outlines the key technical gaps that must be closed for PF-TT-EPE to move beyond concept. electroplasticity springback SDG Sheet metal forming Springback reduction Pulse forming Process failure Sustainable manufacturing Full Text Additional Declarations The authors declare no competing interests. Cite Share Download PDF Status: Posted Version 2 posted You are reading this latest preprint version Show more versions Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. 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Reduction","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":true,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":true,"highlight":"","institution":"","isAcceptedByJournal":false,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true},"keywords":"electroplasticity, springback, SDG, Sheet metal forming, Springback reduction, Pulse forming, Process failure, Sustainable manufacturing","lastPublishedDoi":"10.21203/rs.3.rs-7242556/v2","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-7242556/v2","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eThis work explores the feasibility of inducing springback reduction in AA5754 aluminium alloy sheets using a novel approach: Post-Forming Through-Thickness Electroplastic Effect (PF-TT-EPE). The concept aims to deliver high-energy electrical pulses directly through the sheet thickness via embedded tooling electrodes, enabling stress relaxation without external fixtures or process interruption. While theoretically promising, the experimental campaign encountered critical implementation challenges. Despite establishing a repeatable baseline springback of 11.8\u0026thinsp;\u0026plusmn;\u0026thinsp;0.5\u0026deg;, all attempts to apply pulse trains above ~\u0026thinsp;600 A\u0026middot;ms/mm\u0026sup2; resulted in uncontrolled spark discharge, severe sample damage, and tooling degradation, linked to air gap formation and dielectric breakdown at the interface. At lower energies, the process proved electrically safe but ineffective in reducing springback. These findings highlight the fragility of die-integrated electrical delivery systems and expose the hidden complexity of ensuring stable, conductive contact under forming conditions. Rather than demonstrating success, this study contributes a clear boundary to the applicability of electroplastic forming techniques and outlines the key technical gaps that must be closed for PF-TT-EPE to move beyond concept.\u003c/p\u003e","manuscriptTitle":"High Voltage, High Hopes: A Cautionary Tale of Through-Thickness Electroplastic for Springback Reduction","msid":"","msnumber":"","nonDraftVersions":[{"code":2,"date":"2025-11-03 19:02:04","doi":"10.21203/rs.3.rs-7242556/v2","editorialEvents":[{"type":"communityComments","content":0}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true}},{"code":1,"date":"2025-08-21 14:23:47","doi":"10.21203/rs.3.rs-7242556/v1","editorialEvents":[{"type":"communityComments","content":0}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true}}],"origin":"","ownerIdentity":"993a177b-b81a-458a-80ce-b11b22c702c1","owner":[],"postedDate":"November 3rd, 2025","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"posted","subjectAreas":[],"tags":[],"updatedAt":"2025-10-04T17:08:31+00:00","versionOfRecord":[],"versionCreatedAt":"2025-11-03 19:02:04","video":"","vorDoi":"","vorDoiUrl":"","workflowStages":[]},"version":"v2","identity":"rs-7242556","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-7242556","identity":"rs-7242556","version":["v2"]},"buildId":"8U1c8b4HqxoKbykW_rLl7","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}