Abstract: Aluminum sheet stamping processes are provided that can include heating an aluminum sheet to a first temperature that is greater than ambient temperature; quenching the aluminum sheet to cool the aluminum sheet to a second temperature that is less than the first temperature; after the quenching allowing the aluminum sheet to rest at ambient temperature for at least 24 hours; and stamping the aluminum sheet to form a stamped component. Stamped aluminum components including one or more portions having an HRB hardness of greater than 87 are also provided. Processes are also provided for fabricating an aluminum component from an aluminum sheet. The processes can include modifying formability of at least one discrete portion of an aluminum sheet, and compressing and/or expanding at least a portion of the one discrete portion to form a fabricated component. The fabricated component can include at least one aluminum member comprising a compressed and/or expanded modified discrete portion.

Abstract: A surface modification to prevent oxide scale spallation is disclosed. The surface modification includes a ferritic stainless steel substrate having a modified surface. A cross-section of the modified surface exhibits a periodic morphology. The periodic morphology does not exceed a critical buckling length, which is equivalent to the length of a wave attribute observed in the cross section periodic morphology. The modified surface can be created using at least one of the following processes: shot peening, surface blasting and surface grinding. A coating can be applied to the modified surface.