Superplastic forming of Ti6Al4V alloy using ZrO_(2)-TiO_(2) ceramic die with adjustable linear thermal expansion coefficient

Firstly,the relation between the coefficient of thermal expansion(CTE)and the volume fraction of TiO_(2) was investigated, and also the influence of relative density of ceramic on the CTE was studied.The results show that the volume fraction of TiO_(2) and the relative density both make influence on the CTE of ZrO_(2)-TiO_(2) ceramic.According to the results,the ZrO_(2)-TiO_(2)(volume fraction of TiO_(2) is 27%)ceramic die with the similar CTE(8.92×10^(-6) ℃^(-1))to Ti6Al4V was fabricated.Secondly,to evaluate the dimensional accuracy of the workpiece superplastically formed,the Ti6Al4V impression experiment was performed.The result shows that the dimensional inaccuracy of workpiece is 0.003.Thirdly,in order to evaluate the practicability,the experiment of superplastic forming Ti6Al4V using ZrO_(2)-TiO_(2) cylinder ceramic die was carried out.The Ti6Al4V cylinder shows good shape retention and surface quality,and high dimensional accuracy.The ceramic dies seem to be adequate for superplastic forming the high accuracy Ti6Al4V, and the trials have confirmed the potential of the ZrO_(2)-TiO_(2) ceramic die.

SUPERPLASTIC FORMING AND AP-PLICATION OF GH4169 SUPERALLOY

The superplastic forming and application of GH4169 superalloy are studied. It is shown that for the typical superplastic forming strain rates of 10- 3 s 1 to 10- 4 s -1, the available engineering strains of the fine-grain GH4169 superalloy are always higher than 250% within wide temperature scopes (920 -980℃), and the maximum elongation to failure obtained is 513%. Dynamic grain growth is presented during superplastic deforming for the alloy, and the grain becomes larger with the increase of the strain. A GH4169 fuel manifold of an aerocraft is superplastically formed, and the superplastically formed GH4169 mainfold is tested by 30 MPa hydraulic pressure for 10 min. So some GH4169 alloy complex components can be superplastically formed in the aerospace industry to decrease the costs of fabricating these components.

Effects of Heating Rate on the Process Parameters of Superplastic Forming for Zr_(55)Cu_(30)Al_(10)Ni_5

We investigated the effects of heating rate on the process parameters of superplastic forming for Zr55Cu30Al10Ni5 by differential scanning calorimetry. The continuous heating and isothermal annealing analyses suggested that the temperatures of glass transition and onset crystallization are heating rate-dependent in the supercooled liquid region. Then, the time-temperature-transformation diagram under different heating rates indicates that increasing the heating rate can lead to an increase of the incubation time at the same anneal temperature in the supercooled liquid region. Based on the Arrhenius relationship, we discovered that the incubation time increases by 1.08-1.11 times with double increase of the heating rate at the same anneal temperature, and then verified it by the data of literatures and the experimental results. The obtained curve of the max available incubation time reveals that the incubation time at a certain anneal temperature in the supercooled liquid region is not infinite, and will increase with increasing heating rate until this temperature shifts out of the supercooled liquid region because of exceeding critical heating rate. It is concluded that heating rate must be an important processing parameter of superplastic forming for Zr55Cu30Al10Ni5.

Deformation Behavior of Zr_(65)Cu_(17.5)Ni_(10)Al_(7.5)in Superplastic Forming with Silicon Mould: Simulation and Application

We investigated the deformation behaviors of Zr_65Cu_17.5Ni_10Al_7.5 in superplastic forming in silicon mould via numerical modeling and experiments. The data needed for the constitutive formulation were obtained from compressive tests to establish a material library for finite-element simulation using a DEFORM 3D software. A constant speed forming process of a micro gear was modeled where the loading force, feature size and amount of deformation in the micro gear in silicon mould were analyzed in detail for the optimal requirements of micro gear forming and the protection of silicon mould. Guided by the modeling parameters, an amorphous metal micro gear was successfully obtained by our home-made superplastic forming system with the optimized parameters （temperature of 683 K, top speed of 0.003 mm/s until the load force reaching limiting value at 1960 N, and a gradually decelerating process for holding the force to the end）. Our work gives a good example for optimization of superplastic forming and fabrication of BMGs in microparts.

Superplastic Forming and Diffusion Bonding for Sandwich Structure of Ti-6Al-4V Alloy

Superplastic forming and diffusion bonding (SPF/DB) is a well-established process for the manufacture of components almost exclusively from Ti-6AI-4V sheet material. The sandwich structure of Ti-6AI-4V alloy is investigated. The effects of the microstructure on the SPF/DB process were discussed. The microstructure at the interfaces and the distribution of thickness were researched.

Surface Modelling and Mesh Generation for Simulating Superplastic Forming

This paper presents an approach which enables surface modelling, mesh generation and the Finite Element (FE) analysis to be integrated together to simulate superplastic forming process for complex shaped components. Techniques have been developed to generate an FE mesh over non-four-sided surface areas, the boundaries of which are Bezier curves of arbitrary degree, using a consistent expression. Theoretical evidence is given to determine the number of Bezier triangular patches required for accurately re-constructing die surfaces within a commercial FE solver. The developed techniques have been successfully used in determining the process parameters for forming a 3D rectangular box.

Superplastic Microforming of Zn-A122 Alloy Ribs

Research on microforming of fine-grained superplastic Zn-AI22 alloy was carried out in this paper by means of superplastic forming. With the selected material, microformability tests have been carried out with the specially developed evaluation method by using two kinds of stainless steel dies. With these dies, micro-extrusion tests have been carried out and the characteristics of microformability of the material have been clarified. Effects of processing parameters and die structure on forming have been analyzed. SEM and metallographic microscope have been used to analyze the formed specimens. Through analysis of flow lines of the formed specimen, behavior of material could be understood well.

MODELING OF SUPERPLASTIC FORMING PROCESS FOR ALUMINUM ALLOYS WITH STRAIN HARDENING EFFECT

Superplastic forming of a thin sheet into complex shape is an important manufacturing process especially in aerospace industry. The main objective of modeling the superplastic forming process is to predict the forming pressure-time cycle to maintain the optimum strain rate and the resulting thickness distribution. There have been many attempts to model superplastic forming process using the various techniques including finite element method. However, most of these attempts so far have disregarded the strain hardening effect which occurs in several superplastic materials. In this study,we have used ABAQUS finite element code to predict the suitable processing variables during an axisymmetric cup forming of Supral 100 and 7075Al alloys to examine the strain hardening effects on forming. The performance of numerical results was then compared with the experimental results.

Superplastic formability of Ti-6Al-4V butt-welded plate by laser beam welding

The superplasticity of Ti-6Al-4V butt-welded plates by laser beam welding(LBW)was studied in virtue of hot tensile tests and superplastic bulging tests.Furthermore,microstructural evolution of weld metal upon superplastic forming was systematically analyzed via metallographical tests and scanning electron microscope(SEM).The relation between the microstructure of weld metal and its superplastic ability was discussed.The experimental results show that Ti-6Al-4V butt-welded plates by LBW possess superplasticity.The maximum elongation is up to 154%and the maximum bulge height can be up to 1.81 times the internal radius of the female die.There is an optimum value of the bulge height for bulging gas pressure.

Superplasticity and Diffusion Bonding of Ti_3AI Intermetallic Compounds

The superplasticity of Ti_3Al intermetallic compounds has been investigated in this paper.The Ti-14Al-21Nb ternary alloy showed 477% elongation at the strain rate of 1.49×10^(-5) s^(-1) and 950℃.The elongation of Ti-14Al-21 Nb-3Mo-1V quinary alloy approached to 573% at the strain rate of 4.52×10^(-5) s^(-1) and the same temperature,and it was found that the elongation value in- creased to 1096.4%as temperature was raised up to 980℃ at the same strain rate.Ti_3Al base al- loys were bonded by diffusion bonding technology and good joints were created,the simulated specimens were performed by SPF/DB process.

Porous bulk metallic glass fabricated by powder hot pressing

A synthesis method for the production of porous bulk metallic glass (BMG) was introduced. This method utilizes the su- perplastic forming ability of amorphous powder in the supercooled liquid (SCL) state and intenerating salt mixture as a placeholder to produce BMG foam by using a hot die pressing method. Scanning electron microscope (SEM), X-ray diffraction (XRD) and dif- ferential scanning calorimetry (DSC) were employed to characterize the morphologies of foaming structure, the crystallization and the percentage of crystallization of the as-produced porous BMG. The results suggested that the formation of porous structure by su- perplastic forming process is feasible. Good bonding effect was observed between amorphous powder particles. Less than 6.5% of crystalline phases were formed during hot pressing, and less than 5.5% of residual salt was enclosed in the foam. To remove any re- sidual salt particles, salt preforms with three-dimensional network and good connectivity is necessary.

NICKEL-BASE ALLOY SHEET ALLOYS USED IN AEROSPACE APPLICATIONS

Many gas turbine components are made from nickel alloy sheet. Most are used for directing or containing gases at high temperatures and pressures where metal temperatures can be as high as 1090℃ (2000°F). These applications included combustor systems, casings and liners, transition and exhaust ducting, afterburners, and thrust reversere. Light weight components and sub-assemblies call for alloy sheet with high levels of stength and oxidation resistance. Complex component design calls for excellent ductility and ease of fabrication.The wide range of nickel alloy sheet alloys presently used in aircraft and land-based gas turbines is briefly described and typical properties presented. New sheet alloy developments, involving INCONEL￣* alloys 625LCF, 718SPF and MA754, are presented including the process routes involved and material properties.

Recent Advances in the Hot Working of Titanium Alloys

In this paper, recent advances in titanium alloy processing are reviewed. The casting, superplastic forming, friction stir welding and thermohydrogen processing of titanium alloys are developed. The great cost saving results from using casting comparing with the conventional machining for rings. The superplastic forming of titanium alloys is a feasible manufacturing technology for civil and military aircraft. The friction stir welding leds to the production of fully-formed, high quality friction stirwelds. In thermohydrogen processing, the high diffusivity of hydrogen in titanium is firstly used to add hydrogen to titanium alloys by controlled diffusion from a hydrogen environment , after thermohydrogen processing, to remove it by a controlled vacuum anneal so as to improve processing and mechanical properties.