Higher forming speeds significantly reduce PLC‑related flow lines in 5xxx aluminum sheets and improve subsequent crash performance. When strain rates exceed ~0.6 s⁻¹, EN AW‑5754 can be formed without visible flow‑line patterns, avoiding strain localization and ductility loss from the Portevin–Le Châtelier effect. High‑speed tensile tests on prestrained samples show increased fracture strain and energy absorption at forming speeds near 0.7 s⁻¹. The results highlight forming speed as a direct driver of crash behavior and raise questions on how flow‑line suppression and strain‑rate conditions influence full‑component performance in lightweight automotive structures.
