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