Post on 26-Dec-2015
Advanced Forming Processes
Super plastic Forming
• Ahmed Rabea Ibrahim Sayed • Ahmed Mohamed Saber Salama• Alaa Kamel • Hossam Gamal • Karim Mohamed Khaled• Mohamed Hassan Mohamed• Mohamed Ramdan • Mohsen Eid Mohamed• Ali Ibrahim Mohamed
SUPERPLASTIC FORMING
• DEFINITION• A process for shaping super-plastic
materials, a unique class of crystalline materials that exhibit exceptionally high ductility with neck-free elongation.
• In specific, SPF is a hot forming process in which sheets of superplastic grade aluminum are heated and forced onto or into single surface tools by air pressure.
• Superplastic materials may be stretched in tension to elongations typically in excess of 200% and more commonly in the range of 400–2000%.
• There are rare reports of higher tensile
elongations reaching as much as 8000%. The high ductility is obtained only for superplastic materials and requires both the temperature and rate of deformation (strain rate) to be within a limited range.
Video 1
Super plastic Forming Processes• Cavity Forming This forming process is suitable for the
manufacturing of parts with smooth, convex surfaces.
• Bubble Forming the bubble forming technology is particularly
suitable for parts with high forming depths.• Diaphragm Forming the diaphragm-forming method (DFM) can be used
to reduce the tensile flow stress generated in a specific alloy matrix composite during deformation.
• Types of forming superplastic sheet materials:
• Blow/vacuum forming • Thermo-forming • Deep drawing • Superplastic forming/diffusion
bonding (SPF/DB)
Production Process: SPF
• Need presses 1000, 3000and 8000kN
• SPF/HGPF allows complex shape design with Hi-strength alloys
SPF is a Gas pressure forming process(HGPF)
Typical SPF/ HGPF-Sample Geometries
1. Magnesium ~ AZ 31, MA 2-1, etc.2. Aluminium ~ AA 5083, 7475, etc.3. Titanium ~Ti 6-4, BT6, BT6-S, Ti6-2-4-
2, 4. β 21 S, SP 700, Ti 6-22-22, Ti-MMC5. Ti-Al ~ gamma TiAl6. Steel ~ 1.4462, Lean duplex, etc.7. Nickel ~ IN 718
APPLICATIONS
Aerospace - Lightweight Laminar Structures
• Lip Skins• Engine Nacelle Skins• Bulkheads• Lamp Drums• Wing Tips• Winglets• Leading Edge Ribs• Access Door Inner Skins• Equipment Covers• Facia panels• Acoustic Panels
SPF parts in Al alloy, from Superform website
SPF/DB parts in titanium alloy, Courtesy from Dassault
Automotive - Enclosures, Body in White, Chassis Structures
Door InnersBodysidesDoor RingsEnclosure assembliesTunnelsB PillarsCantrailsRoof StructuresBulkheadsFootwellsExterior Body Panels SPF parts in Al alloy, from Superform website
Rail - Cab Structures, Interior Panels, Doors and Seating
Cab SkinsCab StructuresCab DesksInter End SkinsInter End CanopiesInterior Window MasksInterior Doorway PanelsCab InteriorsDoor Systems SPF parts in Al alloy, from Superform website
Architectural Cladding, Bullnose, Ceiling and Acoustic Panels
Example of decorative panelsRoof panels of the Charléty stadium in Paris
Application in arts
Additional sectors of application
Medical
Tools for SPF forming
Example of non metallic tool for SPF
Lid of metallic container for SPF
Production Process: Diffusion Bonding
DB of Plates;e.g. Heat Exchangers
SPF/DB* Sandwich Design
SPF/DB Sandwich Design
Vessel manufacturing
ADVANTAGES
1. Complex shapes are easily made2. Flexibility in design.3. Low applied stress for forming
HSLA materials. 4. Low capital cost on equipments. 5. Effective material utilization and
savings.
DISADVANTAGES
1. Inferior creep resistance 2. Very slow process.
Thank You